CN118359149B - Fork truck capable of preventing goods from tilting and tilting prevention method - Google Patents
Fork truck capable of preventing goods from tilting and tilting prevention method Download PDFInfo
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Abstract
The invention discloses a forklift for preventing cargoes from tilting and a tilting prevention method, and relates to the technical field of forklifts, comprising a forklift, a mechanical design, sensor application, a control system and an operation interface, wherein the mechanical design, the sensor application and the control system are used for performing tilting prevention control on cargoes, and the operation interface is used for providing real experience control; the sensor comprises an inclination detection module, wherein the inclination detection module is used for monitoring the inclination state of goods in real time; the tilt detection module includes: the sensor unit, the sensor data processing unit and the automatic adjustment fork head mechanism. According to the invention, the inclination detection module is arranged, so that the function of detecting the inclination state of the forklift is realized, the defect that the cargo inclination problem cannot be effectively solved in the traditional forklift design is overcome, the sensing capability of the forklift inclination state in the carrying process is improved, and an accurate data basis is provided for the follow-up inclination prevention measures.
Description
Technical Field
The invention relates to the technical field of forklifts, in particular to a forklift capable of preventing cargoes from tilting and a tilting prevention method.
Background
In modern logistics and warehousing, forklifts often face various cargo handling challenges as an important handling tool. However, one problem that is common in the prior art is that the cargo is prone to tilting during handling, resulting in a series of safety and efficiency problems. These problems may result from cargo of different sizes, shapes and weights, as well as complex and varied working environments. The inclined goods not only increase the risk of carrying, but also can cause damage to the goods and decrease in working efficiency, and even cause potential safety hazards to forklifts and surrounding personnel.
Therefore, the application provides the forklift and the anti-tilting method for preventing the cargo from tilting, which solve the defects in the prior art and improve the capability of the forklift for preventing the cargo from tilting.
1. Patent document CN110240090B discloses a forklift and an anti-tilting method for preventing tilting of goods, which solve the tilting problem of goods and forklift caused by oversized weight and volume of goods and ensure movement of forklift, but the above patent cannot realize the tilting state detection function of forklift.
2. Patent document CN108298481B discloses a control system and method for preventing misoperation of fork of forklift truck in high position, and the above patent realizes effectively preventing safety accident caused by misoperation of forward tilting valve rod when fork is in high position. The safety protection device can combine factors such as the weight of goods and the height of the fork, comprehensively analyze and process, realize safety protection in all directions, further improve the safety of the fork when in high position, but the stability adjustment function of the fork truck can not be realized by the above patent.
3. Patent document CN107840289B discloses a method and a system for limiting lifting of maximum cargo of a forklift, which limit lifting when the lifting weight of the lifted cargo exceeds the maximum lifting weight of the lifted cargo, so that overload operation and accidents can be effectively prevented, but the above patent cannot realize the function of adjusting the gravity center of the forklift in real time.
4. Patent document CN105873849B discloses a control device and a control method for a forklift, and the above patent realizes that the output of the forklift is decelerated or a brake is operated to decelerate the running speed of the vehicle, thereby remarkably reducing the falling risk of the goods, but the above patent cannot realize the function of monitoring the state of the goods in real time.
In summary, the above patent cannot realize the functions of detecting the inclined state of the forklift, adjusting the stability of the forklift, adjusting the center of gravity of the forklift in real time and monitoring the cargo state in real time, which leads to damage of the cargo, decrease in working efficiency, and even potential safety hazards to the forklift and surrounding personnel;
Therefore, the application provides the forklift and the anti-tilting method for preventing the cargo from tilting, which can realize the functions of detecting the tilting state of the forklift, adjusting the stability of the forklift, adjusting the gravity center of the forklift in real time and monitoring the cargo state in real time.
Disclosure of Invention
The invention aims to provide a forklift and an anti-tilting method for preventing cargoes from tilting, so as to solve the technical problems that in the background art, the tilting state detection function, the stability adjustment function, the gravity center real-time adjustment function and the real-time monitoring function for the cargoes cannot be realized, the cargoes are damaged, the working efficiency is reduced, and even potential safety hazards are caused to the forklift and surrounding personnel.
In order to achieve the above purpose, the present invention provides the following technical solutions: the forklift capable of preventing goods from tilting comprises a forklift, a mechanical design, a sensor application, a control system and an operation interface, wherein the mechanical design, the sensor application and the control system are used for performing tilting prevention control on the goods, and the operation interface is used for providing real experience control; the sensor application comprises an inclination detection module, wherein the inclination detection module is used for monitoring the inclination state of goods in real time, the mechanical design, the sensor application and the control system are connected with an operation interface through a signal bus, and the control system is connected with the mechanical design and the sensor application through a data line;
The tilt detection module includes: the sensor unit is connected with the sensor data processing unit through a data signal wire, and the sensor data processing unit is connected with the automatic adjustment fork mechanism through a signal wire;
The sensor unit is installed on the front surface of the outer wall of the forklift and the top of the outer wall of the fork head by adopting the inclination sensor, and the inclination sensor is fixed by using a shockproof bracket, so that the stability of the inclination sensor in movement is kept;
The sensor data processing unit acquires data of the inclination sensor at a speed of 1000 times per second by using a high-speed ADC, eliminates high-frequency noise in the inclination sensor data by using a digital low-pass filter, and analyzes the inclination sensor data to be converted into an inclination angle by using an embedded microcontroller;
A feedback control system is integrated in the automatic fork head adjusting mechanism, the angle data of the inclination sensor is compared with a target angle, and the position of the fork head is adjusted through a sliding rail by using a linear motor;
an electronic stability control module is designed in the control system and is used for adjusting the movement gesture of the forklift, and the electronic stability control module is connected with the inclination detection module through a data line;
The electronic stability control module comprises a gravity center adjusting module, wherein the gravity center adjusting module is used for adjusting the gravity center of the forklift, and the gravity center adjusting module is connected with the electronic stability control module through a signal line.
Preferably, the electronic stability control module includes: the control algorithm unit is connected with the sensor unit and the control system hardware unit through data lines;
The control system hardware unit adopts an embedded controller, supports high-speed data processing, integrates a gyroscope and a triaxial accelerometer, provides accurate attitude information of a vehicle, and integrates a modern communication interface CAN bus so as to realize high-efficiency data communication with other modules;
The control algorithm unit is internally provided with a three-axis PID control algorithm, angle data come from an inclination sensor so as to adjust the speed and the direction of the vehicle, a Kalman filter is used for fusing the gyroscope and the inclination sensor data, a real-time control strategy is introduced, battery electric quantity and load factors are considered, and parameters of the three-axis PID control algorithm are optimized.
Preferably, the gravity center adjusting module includes: structural design, control means and an electric adjusting mechanism;
The hydraulic lifting system and the angle-adjustable design are adopted in the structural design, different heights and inclination requirements are used, and the sliding rail structure is designed, so that the battery compartment can move back and forth and up and down, high-strength and light-weight materials are used, and the self weight of the structure is reduced;
The control means designs an integrated human-computer interface, allows an operator to manually adjust the positions of a cab seat and a battery compartment through a touch screen and a button, realizes an automatic adjustment function through an electro-hydraulic system by utilizing inclination sensor data, and designs an anti-false touch measure in the manual control system and an emergency stop mechanism in the automatic adjustment system in consideration of personnel safety;
The electric adjusting mechanism uses a motor and a hydraulic system, the positions of a cab seat and a battery compartment are adjusted through a controller, a locking device is integrated, the safety of the gravity center adjusting system in the moving process is ensured, a real-time monitoring system is introduced, and the state of the electric adjusting mechanism is monitored to prevent faults.
Preferably, the sensor is further provided with an intelligent cargo stacking module, and the intelligent cargo stacking module is used for monitoring, planning and optimizing cargo stacking states;
The intelligent cargo stacking module comprises: a 3D vision system, a stacking planning algorithm, and a cargo fixture;
The 3D vision system adopts a camera network and is used for capturing the stacking state of goods in real time, integrating the ToF and a structural light sensor and acquiring the three-dimensional shape information of the goods;
Developing an algorithm based on machine learning in a stacking planning algorithm, analyzing data of a 3D visual system, planning an optimal cargo stacking scheme, and introducing a real-time updating strategy to enable the system to dynamically adjust the cargo stacking scheme and adapt to actual carrying scenes;
The goods fixing device is designed to be adjustable according to goods with different sizes and shapes, the clamping force sensor is integrated on the clamping device, the goods fixing state is monitored, and information is transmitted to the control system through the CAN bus.
Preferably, the intelligent cargo stacking module is internally provided with a cargo state real-time monitoring system, the cargo state real-time monitoring system is used for carrying out real-time visual monitoring on the cargo state, and the cargo state real-time monitoring system is connected with the operation interface through a local area network;
The cargo state real-time monitoring system comprises: the video monitoring system is connected with the data transmission analysis through a local area network protocol;
The video monitoring system is provided with a high-definition camera, provides real-time visual monitoring of the cargo state, introduces a real-time image processing algorithm, and monitors the tilting and displacement states of the cargo;
The data transmission analysis selects the high-efficiency data transmission protocol MQTT to ensure the rapid transmission of the real-time monitoring data of the cargo state, and the monitoring data is transmitted to the cloud for deep data analysis and trend monitoring.
Preferably, an operator training warning system is designed in the operation interface, and is used for providing visual operation training and danger warning, and is connected with the operation interface through a data line;
The operator training warning system includes: the simulation training system and the warning system are connected with the inclination detection module through a signal wire;
The simulation training system uses VR technology to build a forklift operation simulation environment, provides real control experience, develops a simulation-based training algorithm, and teaches an operator a method for correctly coping with unstable goods;
an audible and visual warning system is integrated in the warning system, a timely alarm is sent out according to the data of the inclination sensor, a vibration feedback device is introduced into the cab, and an operator is reminded of abnormal conditions of the cargo state through vibration.
Preferably, an environment sensing system is further designed in the sensor application, and is used for sensing and collecting and analyzing the environment state information of the forklift, and the environment sensing system is connected with the operation interface through a signal line;
The environment awareness system includes: the environment sensor unit is connected with the data processing decision system through a data line;
The environment sensor unit is internally integrated with a meteorological sensor for monitoring wind speed and temperature environment factors, optimizing forklift operation, and the periphery of the outer wall of the forklift is provided with laser radar sensors for detecting obstacles around the forklift so as to avoid collision and accidents;
an environment data processing system is introduced into the data processing decision system, the environment sensor data is processed and analyzed in real time, and an automatic decision algorithm is developed so that the forklift can automatically adjust the form strategy according to the environment condition.
Preferably, a real-time monitoring report system is further designed in the operation interface and is used for uploading and backing up monitoring state data and outputting data analysis reports, and the real-time monitoring report system is connected with the electronic stability control module, the control system and the operation interface through data lines;
The real-time monitoring reporting system includes: the real-time monitoring platform is connected with the report analysis unit through a cloud local area network;
the real-time monitoring platform uploads the data of the sensor unit, the environment sensor unit and the video monitoring system to the cloud for storage so as to backup and analyze for a long time, designs an operator interface and displays real-time data, warning information and operation advice;
The report analysis unit utilizes a big data analysis algorithm to carry out deep analysis on the data stored in the cloud, identifies potential problems, designs an automatic generation report system and provides regular operation reports and performance analysis for management staff.
Preferably, the method comprises the steps of:
S1, inclination detection data acquisition: utilizing a tilt detection module to install tilt sensors at fork heads and goods positions of a forklift, and acquiring data of the tilt sensors by using a high-speed ADC;
S2, automatically adjusting a fork head: the gravity center adjusting module is used for designing an electric hydraulic system, and the motor is used for controlling the fork head to move up and down so as to realize automatic adjustment of the cargo inclination state;
s3, intelligent stacking of cargo fixation: the intelligent cargo stacking module is used for designing an adjustable clamping device, automatic and manual adjustment is carried out according to different cargo sizes, and the cargo is ensured to be stably fixed on the fork heads;
S4, operation training real-time monitoring: and (3) building a VR training system in the operator training warning system on the operation interface, and teaching an operator a method for correctly coping with the unstable goods through a simulation scene.
Preferably, the method further comprises the steps of:
S11, a sensor data processing unit applies a digital filtering algorithm, noise interference is reduced, accurate inclination angle information is ensured to be acquired, a triggering condition is set, an inclination prevention system is triggered when the inclination angle reaches a preset threshold value, and subsequent inclination prevention measures are started;
S21, integrating a feedback control system in the automatic adjustment fork mechanism, monitoring the inclination condition of the goods in real time by using data of an inclination sensor, adjusting the output of the electric hydraulic system through closed loop feedback, and ensuring that the adjustment speed of the electric hydraulic system is fast enough by the electric adjustment mechanism in consideration of a speed adjustment strategy so as to react and adjust the goods in time before the goods incline;
S31, an intelligent goods stacking module introduces a 3D vision system and an intelligent stacking algorithm, and an optimal stacking scheme is planned by monitoring and analyzing the shape and the position of goods in real time, so that the possibility of inclination is reduced, a clamping force sensor is integrated, the state of clamping force is monitored, and the goods are ensured to be firmly fixed on the fork heads in the carrying process;
s41, the warning system integrates an audible and visual warning system, timely alarms are sent out according to data of the inclination sensor, real-time inclination information is provided on an operator interface, a high-definition monitoring camera is installed, the state of goods is displayed through the real-time monitoring system, and meanwhile, the goods is fed back to an operator, so that the operator can pay attention to the stability of the goods at any time.
Compared with the prior art, the invention has the beneficial effects that:
1. According to the invention, the inclination detection module is arranged, so that the function of detecting the inclination state of the forklift is realized, the defect that the cargo inclination problem cannot be effectively solved in the traditional forklift design is overcome, the sensing capability of the forklift inclination state in the carrying process is improved, and an accurate data basis is provided for the follow-up inclination prevention measures;
2. According to the invention, the electronic stability control module is arranged, so that the stability adjustment function of the forklift is realized, the unstable state caused by the interference of external factors on the goods in the carrying process is solved, and the stability and safety of the forklift in the carrying process are improved;
3. According to the invention, the gravity center adjusting module is arranged, so that the function of adjusting the gravity center of the forklift in real time is realized, the problem that the traditional forklift is difficult to adapt to gravity center differences of different working scenes and cargoes is solved, the flexibility of the forklift is improved, the gravity center can be dynamically adjusted according to actual needs, and the stability and the operation flexibility in the carrying process are improved;
4. According to the invention, by installing the cargo state real-time monitoring system, the real-time monitoring function of the cargo state is realized, the problems of safety and efficiency possibly brought by abnormal states such as cargo inclination, vibration and the like in the carrying process are solved, the real-time sensing capability of the cargo state is improved, the potential danger to operators and equipment caused by the instability of the cargo in the carrying process is reduced, and the safety and controllability of the carrying process are enhanced.
Drawings
Fig. 1 is a schematic diagram of the working principle of the anti-tilting forklift of the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Example 1
Referring to fig. 1, an embodiment of the present invention is provided: the forklift capable of preventing goods from tilting comprises a forklift, a mechanical design, a sensor application, a control system and an operation interface, wherein the mechanical design, the sensor application and the control system are used for performing tilting prevention control on the goods, and the operation interface is used for providing real experience control; the sensor application comprises an inclination detection module, wherein the inclination detection module is used for monitoring the inclination state of goods in real time, the mechanical design, the sensor application and the control system are connected with an operation interface through a signal bus, and the control system is connected with the mechanical design and the sensor application through a data line;
The tilt detection module includes: the sensor unit is connected with the sensor data processing unit through a data signal wire, and the sensor data processing unit is connected with the automatic adjustment fork mechanism through a signal wire;
The sensor unit is installed on the front surface of the outer wall of the forklift and the top of the outer wall of the fork head by adopting the inclination sensor, and the inclination sensor is fixed by using a shockproof bracket, so that the stability of the inclination sensor in movement is kept;
The sensor data processing unit acquires data of the inclination sensor at a speed of 1000 times per second by using a high-speed ADC, eliminates high-frequency noise in the inclination sensor data by using a digital low-pass filter, and analyzes the inclination sensor data to be converted into an inclination angle by using an embedded microcontroller;
A feedback control system is integrated in the automatic fork head adjusting mechanism, the angle data of the inclination sensor is compared with a target angle, and the position of the fork head is adjusted through a sliding rail by using a linear motor;
an electronic stability control module is designed in the control system and is used for adjusting the movement gesture of the forklift, and the electronic stability control module is connected with the inclination detection module through a data line;
the electronic stability control module comprises a gravity center adjusting module, wherein the gravity center adjusting module is used for adjusting the gravity center of the forklift and is connected with the electronic stability control module through a signal line;
Further, the ADIS16209 MEMS type inclination sensor is adopted, the two sensors are respectively arranged on the front part and the fork head of the forklift, the stability of the sensors in the movement process of the forklift is ensured through the shockproof support, the acquisition of accurate inclination angle data is ensured, the ADS1299 high-speed ADC is used for acquiring the data of the inclination sensor at the speed of 1000 times per second, a digital low-pass Butterworth filter is introduced to eliminate high-frequency noise in the sensor data, the embedded microcontroller analyzes the original data output by the sensors and converts the original data into actual inclination angles, an electro-hydraulic system is designed, wherein the electro-hydraulic system comprises a linear motor, the electro-hydraulic system can control the up-down movement of the fork head through a sliding rail, the automatic adjustment of the inclination state of goods is realized, the feedback control system is integrated, the output of the electro-hydraulic system is adjusted through receiving the sensor data and comparing the actual inclination angle with a target angle, the system timely reacts when the inclination occurs, the stability of the goods is maintained, a high-performance motor driver is selected, the response speed and the accuracy of the electro-hydraulic system are ensured, the fork position can be adjusted rapidly and stably, and the goods can be adjusted.
Example 2
Referring to fig. 1, an embodiment of the present invention is provided: fork truck capable of preventing goods from tilting
The electronic stability control module includes: the control algorithm unit is connected with the sensor unit and the control system hardware unit through data lines;
The control system hardware unit adopts an embedded controller, supports high-speed data processing, integrates a gyroscope and a triaxial accelerometer, provides accurate attitude information of a vehicle, and integrates a modern communication interface CAN bus so as to realize high-efficiency data communication with other modules;
The control algorithm unit is internally provided with a three-axis PID control algorithm, angle data come from an inclination sensor so as to adjust the speed and the direction of a vehicle, a Kalman filter is used for fusing data of the gyroscope and the inclination sensor, a real-time control strategy is introduced, battery electric quantity and load factors are considered, and parameters of the three-axis PID control algorithm are optimized;
further, a TMS320F28379D embedded controller with high performance TI is adopted, a high-sensitivity MPU6050 gyroscope and a triaxial accelerometer are integrated, the gyroscope and the accelerometer monitor the gesture of the vehicle in real time, data are transmitted to a control algorithm unit, the control algorithm unit receives angle data of an inclination sensor, PID control output, namely speed and direction adjustment quantity of the vehicle is calculated, the data of the gyroscope and the inclination sensor are fused by a Kalman filter to obtain a more accurate gesture measurement result, a real-time control strategy unit adjusts parameters of the PID control algorithm according to actual running conditions so as to ensure that the system can keep stable under various working conditions, and the control algorithm unit outputs the adjusted speed and direction instruction and transmits the speed and direction instruction to a driving system to realize stable movement of the vehicle.
Example 3
Referring to fig. 1, an embodiment of the present invention is provided: fork truck capable of preventing goods from tilting
The gravity center adjusting module includes: structural design, control means and an electric adjusting mechanism;
The hydraulic lifting system and the angle-adjustable design are adopted in the structural design, different heights and inclination requirements are used, and the sliding rail structure is designed, so that the battery compartment can move back and forth and up and down, high-strength and light-weight materials are used, and the self weight of the structure is reduced;
The control means designs an integrated human-computer interface, allows an operator to manually adjust the positions of a cab seat and a battery compartment through a touch screen and a button, realizes an automatic adjustment function through an electro-hydraulic system by utilizing inclination sensor data, and designs an anti-false touch measure in the manual control system and an emergency stop mechanism in the automatic adjustment system in consideration of personnel safety;
The electric adjusting mechanism uses a motor and a hydraulic system, positions of a cab seat and a battery compartment are adjusted through a controller, a locking device is integrated, safety of the gravity center adjusting system in the moving process is ensured, a real-time monitoring system is introduced, and the state of the electric adjusting mechanism is monitored to prevent faults;
Further, when the system is started, the seat and the battery bin are at the initial position, the hydraulic lifting system lifts the seat to the standard height, the battery bin is at the standard position, if manual adjustment is needed, an operator selects the height and the angle of the seat and the position of the battery bin through a human-computer interface, the system starts an electric adjustment mechanism according to manual input, the manual adjustment of the seat and the battery bin is realized, the tilt sensor is started to monitor the tilt state of the forklift in real time, sensor data are transmitted to the control system through a control means, the control algorithm analyzes the data of the tilt sensor, the optimal height and the angle of the seat and the position of the battery bin are calculated, the algorithm adjusts a control instruction according to the difference between the actual tilt state and the target state, the electric adjustment mechanism realizes automatic adjustment of the height and the angle of the seat and the movement of the position of the battery bin through a motor and a hydraulic system according to the control instruction, the automatic start of the electric locking mechanism after the adjustment is finished, the seat and the battery bin is ensured to be locked at the selected position, accidental movement is prevented, and the introduced real-time monitoring system monitors the position of the seat and the battery bin through the position sensor is fed back to the control system.
Example 4
Referring to fig. 1, an embodiment of the present invention is provided: the forklift capable of preventing cargoes from tilting is characterized in that an intelligent cargoes stacking module is further designed in the application of the sensor, and the intelligent cargoes stacking module is used for monitoring, planning and optimizing cargoes stacking states;
The intelligent cargo stacking module comprises: a 3D vision system, a stacking planning algorithm, and a cargo fixture;
The 3D vision system adopts a camera network and is used for capturing the stacking state of goods in real time, integrating the ToF and a structural light sensor and acquiring the three-dimensional shape information of the goods;
Developing an algorithm based on machine learning in a stacking planning algorithm, analyzing data of a 3D visual system, planning an optimal cargo stacking scheme, and introducing a real-time updating strategy to enable the system to dynamically adjust the cargo stacking scheme and adapt to actual carrying scenes;
the goods fixing device is designed to an adjustable clamping device aiming at goods with different sizes and shapes, a clamping force sensor is integrated on the clamping device, the goods fixing state is monitored, and information is transmitted to the control system through the CAN bus;
Further, the high-resolution camera network is arranged on the front portion and the side face of the forklift, surrounding environment and cargoes can be captured in an omnibearing manner, the depth sensor is equipped to integrate ToF and the structural light sensor so as to acquire accurate position and shape information of the cargoes, real-time data captured by the camera network and the structural light sensor are transmitted to the control system to form a three-dimensional model of the whole working environment, the control system processes and models the received 3D environment data, including information of positions, shapes, sizes and the like of the cargoes, an intelligent stacking planning algorithm is introduced, the shapes, the sizes, the weights and the target stacking positions of the cargoes are considered, an optimal cargo stacking scheme is planned, the algorithm simultaneously considers the moving capability of the forklift, a path of the forklift is planned, the efficient movement and the task completion in the stacking process are ensured, the adjustable clamping device is adapted to different cargo sizes according to the stacking planning design, the cargo is ensured not to be inclined easily in the carrying process, the clamping force is monitored, the clamping force is ensured to be enough, the cargo is not damaged, the data of the clamping force and the clamping state are transmitted to the control system, and the operator is fed back to the operator in real time so as to ensure firm and stable cargo in the transporting process.
Example 5
Referring to fig. 1, an embodiment of the present invention is provided: the intelligent cargo stacking module is internally provided with a cargo state real-time monitoring system which is used for carrying out real-time visual monitoring on the cargo state and is connected with an operation interface through a local area network;
The cargo state real-time monitoring system comprises: the video monitoring system is connected with the data transmission analysis through a local area network protocol;
The video monitoring system is provided with a high-definition camera, provides real-time visual monitoring of the cargo state, introduces a real-time image processing algorithm, and monitors the tilting and displacement states of the cargo;
The data transmission analysis selects a high-efficiency data transmission protocol MQTT to ensure the rapid transmission of the real-time monitoring data of the cargo state, and the monitoring data is transmitted to the cloud for deep data analysis and trend monitoring;
Further, a plurality of cameras are installed to cover the whole cargo handling area so as to ensure that the cargo is monitored in all directions, the high-resolution cameras are used to acquire clear images, an operator can carefully observe the state and the handling process of the cargo, a video monitoring system transmits image data to a control center in real time so that the operator can observe the state of the cargo in real time, the control center receives real-time video data from the cameras and stores the real-time video data in a database for subsequent analysis and playback, image processing and analysis are carried out on video streams in real time so as to detect the state of the cargo, such as stability, abnormal vibration and the like, a computer vision technology is used to identify the characteristics of the cargo and track the characteristics of the cargo, ensure that the real-time monitoring of the state of the cargo is carried out, an abnormal detection algorithm is introduced, whether abnormal behaviors such as inclination, falling and the like occur in the cargo handling process are monitored, when the abnormal state is monitored, the system triggers a real-time alarm to inform the operator of possible problems in the cloud end so that the operator can react rapidly, the processed data are transmitted to a monitoring interface for transmitting the monitoring data to the monitoring state to the operator and the operator so that the real-time cargo state information can be monitored and remotely monitored.
Example 6
Referring to fig. 1, an embodiment of the present invention is provided: the forklift truck capable of preventing cargoes from tilting is characterized in that a real-time monitoring report system is further designed in the operation interface and is used for uploading and backing up monitoring state data and outputting data analysis reports, and the real-time monitoring report system is connected with the electronic stability control module, the control system and the operation interface through data lines;
The real-time monitoring reporting system includes: the real-time monitoring platform is connected with the report analysis unit through a cloud local area network;
the real-time monitoring platform uploads the data of the sensor unit, the environment sensor unit and the video monitoring system to the cloud for storage so as to backup and analyze for a long time, designs an operator interface and displays real-time data, warning information and operation advice;
The report analysis unit utilizes a big data analysis algorithm to carry out deep analysis on the data stored in the cloud, identify potential problems, design an automatic generation report system and provide regular operation reports and performance analysis for management staff;
Further, various data of the sensor unit, the environment sensor unit and the video monitoring system are collected in real time, including environmental parameters, equipment states, battery information and the like, the real-time monitoring platform receives and integrates the real-time data from each sensor, the data are displayed on the monitoring platform in a chart, a digital form and the like in real time, an operator can intuitively know the current state, when the real-time monitoring platform monitors abnormal conditions, a real-time alarm system is triggered, the operator is notified of possible problems, the real-time monitoring platform transmits the data to a report analysis unit for deep data analysis, the report analysis unit carries out trend analysis on historical data, predicts future change trend of the equipment and the environment states, an abnormality detection algorithm analyzes the real-time data, finds and analyzes possible abnormal conditions, evaluates the equipment performance, generates a performance report, provides maintenance and optimization suggestions, generates a real-time monitoring report based on the real-time data, the trend analysis and the abnormality detection result, provides detailed text and chart form reports, the real-time monitoring report is displayed on the monitoring platform in a visual mode, and the operator can view and analyze the report in real time.
The working principle is that an inclination detection system is firstly provided, and the inclination state of the forklift is monitored in real time through an inclination sensor arranged on the forklift. Once the sensor detects tilting of the truck, the sensor data will be transmitted to the control system. The inclination detection system is aimed at timely sensing and identifying the inclination condition of the forklift and providing an accurate data basis for subsequent inclination prevention measures;
Based on the data of the inclination detection system, the fork truck is equipped with an electronic stability control module. The module is divided into a control system hardware unit and a control algorithm unit. Under the data input of the inclination detection system, the control algorithm unit calculates the adjustment parameters required for realizing the stable state through real-time analysis of the sensor data. The control system hardware unit is responsible for implementing these parameters, and counteracting or reducing the tilting by adjusting the structure of each part of the forklift. The process forms a closed loop feedback system, so that the forklift can realize quick and accurate stable adjustment in an inclined state;
in order to more flexibly cope with different working scenes and requirements, the forklift is also provided with a gravity center adjusting module. This module includes an adjustable cab seat and battery compartment, and an associated motorized adjustment mechanism. According to the data of the inclination detection system and the electronic stability control module, the gravity center adjusting module can adjust the height and the angle of the cab seat and the position of the battery compartment in real time, so that the gravity center of the forklift is adjusted. The adjustment ensures that the forklift can maintain the optimal balance state in the process of carrying the cargoes, and prevents the cargoes from being inclined to influence the stability of the forklift. The cooperative work of the whole system enables the forklift to efficiently and flexibly cope with various working scenes, and safe handling of goods is guaranteed.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.
Claims (6)
1. Prevent fork truck of goods slope, its characterized in that: the system comprises a forklift, a mechanical design, a sensor application, a control system and an operation interface, wherein the mechanical design, the sensor application and the control system are used for carrying out anti-tilting control on goods, and the operation interface is used for providing real experience control; the sensor application comprises an inclination detection module, wherein the inclination detection module is used for monitoring the inclination state of goods in real time, the mechanical design, the sensor application and the control system are connected with an operation interface through a signal bus, and the control system is connected with the mechanical design and the sensor application through a data line;
The tilt detection module includes: the sensor unit is connected with the sensor data processing unit through a data signal wire, and the sensor data processing unit is connected with the automatic adjustment fork mechanism through a signal wire;
The sensor unit is installed on the front surface of the outer wall of the forklift and the top of the outer wall of the fork head by adopting the inclination sensor, and the inclination sensor is fixed by using a shockproof bracket, so that the stability of the inclination sensor in movement is kept;
The sensor data processing unit acquires data of the inclination sensor at a speed of 1000 times per second by using a high-speed ADC, eliminates high-frequency noise in the inclination sensor data by using a digital low-pass filter, and analyzes the inclination sensor data to be converted into an inclination angle by using an embedded microcontroller;
A feedback control system is integrated in the automatic fork head adjusting mechanism, the angle data of the inclination sensor is compared with a target angle, and the position of the fork head is adjusted through a sliding rail by using a linear motor;
an electronic stability control module is designed in the control system and is used for adjusting the movement gesture of the forklift, and the electronic stability control module is connected with the inclination detection module through a data line;
the electronic stability control module comprises a gravity center adjusting module, wherein the gravity center adjusting module is used for adjusting the gravity center of the forklift and is connected with the electronic stability control module through a signal line;
The sensor is characterized in that an intelligent cargo stacking module is also designed in the application of the sensor, and the intelligent cargo stacking module is used for monitoring, planning and optimizing cargo stacking states;
The intelligent cargo stacking module comprises: a 3D vision system, a stacking planning algorithm, and a cargo fixture;
The 3D vision system adopts a camera network and is used for capturing the stacking state of goods in real time, integrating the ToF and a structural light sensor and acquiring the three-dimensional shape information of the goods;
Developing an algorithm based on machine learning in a stacking planning algorithm, analyzing data of a 3D visual system, planning an optimal cargo stacking scheme, and introducing a real-time updating strategy to enable the system to dynamically adjust the cargo stacking scheme and adapt to actual carrying scenes;
the goods fixing device is designed to an adjustable clamping device aiming at goods with different sizes and shapes, a clamping force sensor is integrated on the clamping device, the goods fixing state is monitored, and information is transmitted to the control system through the CAN bus;
The intelligent cargo stacking module is internally provided with a cargo state real-time monitoring system which is used for carrying out real-time visual monitoring on the cargo state and is connected with an operation interface through a local area network;
The cargo state real-time monitoring system comprises: the video monitoring system is connected with the data transmission analysis through a local area network protocol;
The video monitoring system is provided with a high-definition camera, provides real-time visual monitoring of the cargo state, introduces a real-time image processing algorithm, and monitors the tilting and displacement states of the cargo;
The data transmission analysis selects a high-efficiency data transmission protocol MQTT to ensure the rapid transmission of the real-time monitoring data of the cargo state, and the monitoring data is transmitted to the cloud for deep data analysis and trend monitoring;
An operator training warning system is designed in the operation interface and is used for providing visual operation training and danger warning, and the operator training warning system is connected with the operation interface through a data line;
The operator training warning system includes: the simulation training system and the warning system are connected with the inclination detection module through a signal wire;
The simulation training system uses VR technology to build a forklift operation simulation environment, provides real control experience, develops a simulation-based training algorithm, and teaches an operator a method for correctly coping with unstable goods;
An audible and visual warning system is integrated in the warning system, a timely alarm is sent out according to the data of the inclination sensor, a vibration feedback device is introduced into the cab, and an operator is reminded of abnormal conditions of the cargo state through vibration;
The sensor application is also internally provided with an environment sensing system which is used for sensing and collecting and analyzing the data of the environment state information of the forklift, and the environment sensing system is connected with the operation interface through a signal line;
The environment awareness system includes: the environment sensor unit is connected with the data processing decision system through a data line;
The environment sensor unit is internally integrated with a meteorological sensor for monitoring wind speed and temperature environment factors, optimizing forklift operation, and the periphery of the outer wall of the forklift is provided with laser radar sensors for detecting obstacles around the forklift so as to avoid collision and accidents;
an environment data processing system is introduced into the data processing decision system, the environment sensor data is processed and analyzed in real time, and an automatic decision algorithm is developed so that the forklift can automatically adjust the form strategy according to the environment condition.
2. A forklift for preventing tilting of cargo according to claim 1, wherein: the electronic stability control module includes: the control algorithm unit is connected with the sensor unit and the control system hardware unit through data lines;
The control system hardware unit adopts an embedded controller, supports high-speed data processing, integrates a gyroscope and a triaxial accelerometer, provides accurate attitude information of a vehicle, and integrates a modern communication interface CAN bus so as to realize high-efficiency data communication with other modules;
The control algorithm unit is internally provided with a three-axis PID control algorithm, angle data come from an inclination sensor so as to adjust the speed and the direction of the vehicle, a Kalman filter is used for fusing the gyroscope and the inclination sensor data, a real-time control strategy is introduced, battery electric quantity and load factors are considered, and parameters of the three-axis PID control algorithm are optimized.
3. A forklift for preventing tilting of cargo according to claim 1, wherein: the gravity center adjusting module includes: structural design, control means and an electric adjusting mechanism;
The hydraulic lifting system and the angle-adjustable design are adopted in the structural design, different heights and inclination requirements are used, and the sliding rail structure is designed, so that the battery compartment can move back and forth and up and down, high-strength and light-weight materials are used, and the self weight of the structure is reduced;
The control means designs an integrated human-computer interface, allows an operator to manually adjust the positions of a cab seat and a battery compartment through a touch screen and a button, realizes an automatic adjustment function through an electro-hydraulic system by utilizing inclination sensor data, and designs an anti-false touch measure in the manual control system and an emergency stop mechanism in the automatic adjustment system in consideration of personnel safety;
The electric adjusting mechanism uses a motor and a hydraulic system, the positions of a cab seat and a battery compartment are adjusted through a controller, a locking device is integrated, the safety of the gravity center adjusting system in the moving process is ensured, a real-time monitoring system is introduced, and the state of the electric adjusting mechanism is monitored to prevent faults.
4. A forklift for preventing tilting of cargo according to claim 1, wherein: the operation interface is internally provided with a real-time monitoring report system which is used for uploading and backing up monitoring state data and outputting data analysis reports, and the real-time monitoring report system is connected with the electronic stability control module, the control system and the operation interface through data lines;
The real-time monitoring reporting system includes: the real-time monitoring platform is connected with the report analysis unit through a cloud local area network;
the real-time monitoring platform uploads the data of the sensor unit, the environment sensor unit and the video monitoring system to the cloud for storage so as to backup and analyze for a long time, designs an operator interface and displays real-time data, warning information and operation advice;
The report analysis unit utilizes a big data analysis algorithm to carry out deep analysis on the data stored in the cloud, identifies potential problems, designs an automatic generation report system and provides regular operation reports and performance analysis for management staff.
5. A method for preventing tilting of a forklift for preventing tilting of goods, which is applicable to the forklift for preventing tilting of goods according to any one of claims 1 to 4, and is characterized in that: the method comprises the following steps:
S1, inclination detection data acquisition: utilizing a tilt detection module to install tilt sensors at fork heads and goods positions of a forklift, and acquiring data of the tilt sensors by using a high-speed ADC;
S2, automatically adjusting a fork head: the gravity center adjusting module is used for designing an electric hydraulic system, and the motor is used for controlling the fork head to move up and down so as to realize automatic adjustment of the cargo inclination state;
s3, intelligent stacking of cargo fixation: the intelligent cargo stacking module is used for designing an adjustable clamping device, automatic and manual adjustment is carried out according to different cargo sizes, and the cargo is ensured to be stably fixed on the fork heads;
S4, operation training real-time monitoring: and (3) building a VR training system in the operator training warning system on the operation interface, and teaching an operator a method for correctly coping with the unstable goods through a simulation scene.
6. The tilting prevention method of a forklift for preventing tilting of cargoes according to claim 5, wherein: the method further comprises the steps of:
S11, a sensor data processing unit applies a digital filtering algorithm, noise interference is reduced, accurate inclination angle information is ensured to be acquired, a triggering condition is set, an inclination prevention system is triggered when the inclination angle reaches a preset threshold value, and subsequent inclination prevention measures are started;
S21, integrating a feedback control system in the automatic adjustment fork mechanism, monitoring the inclination condition of the goods in real time by using data of an inclination sensor, adjusting the output of the electric hydraulic system through closed loop feedback, and ensuring that the adjustment speed of the electric hydraulic system is fast enough by the electric adjustment mechanism in consideration of a speed adjustment strategy so as to react and adjust the goods in time before the goods incline;
S31, an intelligent goods stacking module introduces a 3D vision system and an intelligent stacking algorithm, and an optimal stacking scheme is planned by monitoring and analyzing the shape and the position of goods in real time, so that the possibility of inclination is reduced, a clamping force sensor is integrated, the state of clamping force is monitored, and the goods are ensured to be firmly fixed on the fork heads in the carrying process;
s41, the warning system integrates an audible and visual warning system, timely alarms are sent out according to data of the inclination sensor, real-time inclination information is provided on an operator interface, a high-definition monitoring camera is installed, the state of goods is displayed through the real-time monitoring system, and meanwhile, the goods is fed back to an operator, so that the operator can pay attention to the stability of the goods at any time.
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