Floor Conveyor

Abstract

Systems and methods for operation of a floor conveyor, the floor conveyor including a sensor device, the systems and methods include providing a predetermined detection zone outside at least a section of the circumference of the floor conveyor for detection of foreign objects positioned inside the predetermined detection zone, wherein the predetermined detection zone is arranged to end at a first predetermined distance from a predetermined object. The method further comprises extending the predetermined detection zone with a second predetermined distance within which the predetermined object is expected to be positioned. The method further comprises implementing security measures on the floor conveyor, if the predetermined object is not detected within the extended predetermined detection zone.

Claims

1. A method for operation of a floor conveyor, the floor conveyor including a sensor device, the method comprising the steps of: providing a predetermined detection zone outside at least a section of the circumference of the floor conveyor for detection of objects positioned inside the predetermined detection zone by the sensor device, wherein the predetermined detection zone is arranged to end at a first predetermined distance from an object, extending the predetermined detection zone with a second predetermined distance within which the object is expected to be positioned, implementing security measures on the floor conveyor, if the object is not detected within the extended predetermined detection zone by the sensor device, otherwise allow continued operation of the floor conveyor.

2. The method according to claim 1, wherein the object is the surface on which the floor conveyor is supported.

3. The method according to claim 1, wherein the security measures comprise complete shutdown of the floor conveyor.

4. The method according to claim 1, wherein the security measures involves shut down of all functions of the floor conveyor that require detection of foreign objects inside a predetermined zone outside at least a section of the circumference of the floor conveyor for their operation.

5. The method according to claim 1, wherein the second predetermined distance is longer than the first predetermined distance, and no longer than 1.5 times than the first predetermined distance.

6. The method according to claim 1, wherein the sensor device is the sole sensor device on board the floor conveyor that can detect objects inside a predetermined zone outside at least a section of the circumference of the floor conveyor and the sole sensor device able to detect objects outside the circumference of the floor conveyor.

7. The method according to claim 1, wherein the predetermined detection zone is provided as a plane.

8. The method of claim 1, further comprising providing a program stored in a non-transitory computer-readable medium, the control unit of the floor conveyor executing the method.

9. A floor conveyor comprising: a sensor device for detecting objects inside a predetermined zone outside at least a section of the circumference of the floor conveyor, and a sensor control unit, wherein the sensor device is arranged to be able to provide the sensor control unit with sensor data, wherein the sensor control unit is arranged to test the sensor device by implementing the method according to claim 1.

10. The floor conveyor according to claim 9, wherein the sensor device is mounted at an angle with regard to the horizontal plane.

11. The floor conveyor according to claim 9, wherein the sensor device is mounted at a predetermined distance from the surface on which the floor conveyor is supported, wherein this distance is sufficient for the sensor device to detect objects on a first side, a section of a second side, and a section of a third side of the floor conveyor, wherein the first side is positioned opposite a load carrier.

12. The floor conveyor according to claim 9, wherein the sensor device is able to detect objects projecting into the predetermined zone positioned outside at least a section of the circumference of the floor conveyor for detection of objects positioned inside the predetermined zone by the sensor device, wherein the predetermined zone is provided as a predetermined plane.

13. The floor conveyor according to claim 9, wherein the sensor device is mounted in a central position on a longitudinal symmetry line of the floor conveyor.

14. The floor conveyor according to claim 9, wherein the sensor device is a laser sensor.

15. The floor conveyor according to claim 9, wherein the sensor device is the sole sensor device on board the floor conveyor that can detect objects inside a predetermined zone outside at least a section of the circumference of the floor conveyor, and the sole sensor device able to detect objects outside the circumference of the floor conveyor.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0032] FIG. 1 shows a floor conveyor according to the present disclosure.

[0033] FIG. 2 shows a floor conveyor according to FIG. 1, shown with an extended plane.

[0034] FIG. 3 shows a floor conveyor according to FIGS. 1 and 2, shown from another angle.

[0035] FIG. 4 shows a floor conveyor according to FIGS. 1-3, shown from above.

[0036] FIG. 5 shows a method according to the present disclosure.

DETAILED DESCRIPTION

[0037] The present disclosure relates to a floor conveyor comprising a sensor device for detecting objects. The floor conveyor may be any type of floor conveyor that is operable with such a sensor device. Examples of such floor conveyors are order picker trucks, stacker trucks, pallet trucks, reach trucks, or tow tractors having a wagon or a space for material handling. The sensor device of the disclosure can detect objects that enter or are positioned within a certain distance of the floor conveyor. One exemplary usage of a floor conveyor with a sensor device according to the disclosure is an order picker truck that may be used with a remote control. In some embodiments, a sensor device may be required when using the remote control. However, the use of a remote control is not mandatory for the disclosure.

[0038] The present disclosure relates to a method as seen in FIG. 5. The present disclosure thus relates to a method for operation of a floor conveyor, provided with a sensor device, comprising the steps of: providing a predetermined detection zone outside at least a section of the circumference of the floor conveyor for detection of objects positioned inside the predetermined detection zone by the sensor device, wherein the predetermined detection zone may be arranged to end at a first predetermined distance from a predetermined object, extending the predetermined detection zone with second predetermined distance within which the predetermined object is expected to be positioned, and implementing security measures on the floor conveyor, if the predetermined object is not detected within the extended predetermined detection zone by the sensor device, otherwise allow continued operation of the floor conveyor.

[0039] The detection zone may be provided by the sensor device. The aim for the detector may be to detect objects that are positioned outside the circumference of the floor conveyor. The circumference is best seen in FIG. 4 of the disclosure as number 13. That is the circumference may be construed as being the outer contour of the floor conveyor. Thus the step of providing may be setting the normal operation of the floor conveyor when in material handling operations. The predetermined zone may end at a first predetermined distance from a predetermined object. In the next step of extending, the predetermined zone may be extended. The extension may be made with a second predetermined distance. The second predetermined distance may be based on the position of an expected object. In most cases the second predetermined distance may be the same as the first predetermined distance. Thus, expected means that the method may rely on an object that should be present when performing the method. However, the second predetermined distance may be made longer than the first predetermined distance. This may avoid unnecessary fault detection of the sensor device. It should be understood that it may be important that the second predetermined distance is not too long, because if the sensor device is not in the correct position the test may indicate that no detection of the predetermined object is achieved. As an example the second predetermined distance may not be more than 1.5 times the first predetermined distance.

[0040] In some embodiments the expected object may be an object to which the distance is more or less constant over time. In some situations it may be beneficial for the predetermined object to be on the surface on which the floor conveyor is supported, e.g., the floor or the tarmac on which the floor conveyor is operating. This provides for a very repeatable and easy way of executing the method. It is of course thinkable to perform the method by using another object such as a wall or a pillar as the object. In this case the method may require that the position of the floor conveyor in relation to the object is known when the method is performed. The position may be known by positioning the floor conveyor in a marked test position, or by manually entering the position into a control unit of the floor conveyor, or by sending the position to the floor conveyor through an interface, or determining the position by a positioning system in the area where the floor conveyor is operating.

[0041] When the predetermined object is not detected by the extending step, security measures may be applied according to the method. One security measure possible may be to completely shut down the floor conveyor. However, it may also be possible to limit the functions of the floor conveyor. For example, it may be beneficial that the functions of the floor conveyor that are dependent on the function of the sensor device be shut down. Functions that are dependent on the sensor device may be, for example, allowable speeds of travel above a certain level, independent travel of the floor conveyor without the operator using the normal controls, e.g., using a remote control, of the floor conveyor, automatic travel of the floor conveyor following an object at one side, e.g., a storage shelf, etc.

[0042] The present disclosure also relates to a computer executable software that when executed on a floor conveyor, the disclosure performs the method as discussed above. By implementing the method as a software the method can be made more independent from interaction of an operator and thus the testing of the sensor device can be made more reliable. The method can be performed at predetermined intervals without interaction of any operator etc. For example, in some situations it may be beneficial that the method is executed at start-up of the floor conveyor. This may be implemented when executing the method by the control unit of the floor conveyor.

[0043] In FIG. 1, there is disclosed the floor conveyor 1 with the sensor device 2. The floor conveyor 1 further comprises the control unit 3 that may be able to control the sensor device 2. The sensor device 2 may detect objects within the predetermined detection zone 4. The zone 4 may be best viewed in FIG. 3, but the zone 4 can also be seen from the side in FIG. 1. The sensor device 2 may be mounted at an angle to the horizontal plane. The range of the detection zone 4 may be in the lower part ended at an end side 5. Side 5 may be positioned above the surface 6 on which the floor conveyor 1 is supported, more specifically the side 5. The side 5 thus leaves a gap 7 to the surface 6. In some embodiments, this may be made in practice by limiting the time slot for which measurement is made of the sent out sensor waves from the sensor device 2. The reason for providing the first predetermined distance point or side 5 may be for the reason that otherwise a constant signal may be generated from the surface 6, when operating the floor conveyor 1. For the present disclosure it may not be important how the shape of the zone is constituted. The shape of the zone 4 in FIG. 3 is only given as an example. The zone 4 may be advantageously constituted as a plane.

[0044] FIG. 2 shows the core part of the disclosure. The zone 4 of FIG. 1 may be extended during the test of the sensor device 2, to an extended zone 4a as seen in FIG. 2. If the sensor device 2 is functioning according to predetermined requirements, a signal will be obtained from the surface 6. The sensor device 2 may then send a signal to the control unit 3 that can acknowledge continued operation without limitations. The gap 7 may be covered by the extended zone 4a from the line 9 to the line 10 essentially ending on the surface 6. In some embodiments it may be beneficial for the distance of extension to be a little bit longer than the distance between line 9 and 10, to safeguard that an expected object is within the extend zone 4a. If the sensor device is not operating correctly, or pointing in the wrong direction, no signal will be detected by the sensor device 2. Then the control unit 3 will not get detection data and may not take measures on this, as will be further explained below.

[0045] The angle may be adjusted for the use of the floor conveyor. If a smaller angle is used the detection zone 4 will have a longer range on side 13a, FIG. 4, of the floor conveyor. If a larger angle is used, a shorter detection zone 4 may be achieved. By the angle it provides for that only one sole sensor may be used for detection of objects supported on the surface 6 despite that the sensor device may be positioned higher up on the floor conveyor 1. In some embodiments of the floor conveyor 1, other than the sensor device 2, the floor conveyor 1 has no further sensor device for detecting objects. In these embodiments, the sensor device 2 may then be the sole sensor device for this purpose on the floor conveyor 1.

[0046] The sensor device 2 may be mounted at a predetermined distance 14, shown in FIG. 1, from the surface 6. The distance 14 may be advantageously at the upper portion of the housing of the floor conveyor 1. It should be understood that lower positions may be possible, but it may be desired to keep the sensor device 2 away from the surface 6. It may also be beneficial to have the sensor device 2 higher in order to be able to detect objects protruding in space and not necessarily being supported on the surface 6.

[0047] In some situations it may be beneficial to have a sensor device that can detect objects positioned or/projecting within a plane 4. The plane 4 allows for a good coverage of the zone to be detected. Existing detectors that essentially lock in a more restricted beam in one direction may be more limited and may not be as efficient as when applying a plane, such as plane 4. Further, by detecting in a plane, such as plane 4, and not in a volume, the sensor device can be installed for optimal operation, i.e., the angle of the plane 4 may be used for extension and reduction of the desired detection zone in longitudinal direction of the plane 4. The extended zone 4a may also be a plane.

[0048] In some embodiments the position of the sensor device 2 may be in a central position on the longitudinal symmetry line 15 of the floor conveyor 1. By mounting in this position, it may be simpler to achieve a predetermined detection zone 4 that can detect objects on sides 13a, 13b, and 13c of the floor conveyor 1, FIG. 4.

[0049] A laser sensor 2 may be advantageously used as the sensor device 2. The laser sensor may be applied to monitor a plane. Any laser sensor applicable to this is usable. In some situations it may be beneficial that the laser sensor 2 can monitor more than 180 degrees in front of it, advantageously more than 240 degrees, or even more advantageously more than 300 degrees. This allows for detecting objects on at least sections of side 13a, 13b, and 13c. In particular when the sensor device 2 is mounted a bit retracted from the most protruding point of any side to be monitored, such as side 13a as seen in FIG. 1.

[0050] The present disclosure describes embodiments with reference to the Figures, in which like numbers represent the same or similar elements. Reference throughout this specification to one embodiment, an embodiment, or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, appearances of the phrases in one embodiment, in an embodiment, and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

[0051] The described features, structures, or characteristics of the embodiments may be combined in any suitable manner in one or more embodiments. In the description, numerous specific details are recited to provide a thorough understanding of the embodiments. One skilled in the relevant art will recognize, however, that the embodiments may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the embodiments.

[0052] Although the above discussion discloses various exemplary embodiments, it should be apparent that those skilled in the art can make various modifications that will achieve some of the disclosed advantages without departing from the true scope of the disclosure.