Multiple zone sensing for materials handling vehicles

{
  "publication_number": "US9908527B2",
  "country": "US",
  "kind": "B2",
  "title": "Multiple zone sensing for materials handling vehicles",
  "abstract": "A materials handling vehicle includes at least one contactless obstacle sensor that scans at least two speed zones, each speed zone being defined in an area at least partially in front of a forward traveling direction of the vehicle and being associated with a unique predetermined maximum speed greater than zero (0) miles per hour. A controller that receives information obtained from the at least one obstacle sensor and, if the vehicle is traveling under remote control, the controller is configured to limit the vehicle speed to the predetermined maximum speed of a corresponding one of the at least two speed zones based upon the detection of an obstacle in that speed zone.",
  "claims": [
    "1. A materials handling vehicle capable of supplemental remote control comprising: a power unit for driving the vehicle; a load handling assembly; a receiver at the vehicle for receiving transmissions from a corresponding remote control device, the transmissions comprising at least a first type signal designating a travel request requesting the vehicle to travel; at least one contactless obstacle sensor on the vehicle operable to scan at least two speed zones, each speed zone being defined in an area at least partially in front of a forward traveling direction of the vehicle and being associated with a unique predetermined maximum speed greater than zero (0) miles per hour; and a controller that communicates with the receiver and with a traction control system of the vehicle to operate the vehicle under remote control in response to receiving travel requests from the remote control device, wherein the controller receives information obtained from the at least one obstacle sensor and, if the vehicle is traveling under remote control in response to a travel request from the remote control device, the controller is configured to limit the vehicle speed to the predetermined maximum speed of a corresponding one of the at least two speed zones based upon the detection of an obstacle in that speed zone.",
    "2. The materials handling vehicle according to claim 1, wherein: the at least one obstacle sensor further scans a stop zone; and if the vehicle is traveling under remote control in response to a travel request from the remote control device, the controller is configured to implement a stop action to stop the vehicle if an obstacle is detected in the stop zone.",
    "3. The materials handling vehicle according to claim 2, wherein: the controller is further configured to refuse to operate the vehicle under remote control in response to receipt of a travel request received from the remote control device if an obstacle is detected within the stop zone before the vehicle begins travel.",
    "4. The materials handling vehicle according to claim 1, wherein: the predetermined speed associated with the first one of the at least two speed zones comprises a first predetermined speed; and the controller is further configured to accelerate the vehicle to a predetermined maximum speed that is greater than the first predetermined speed if the vehicle is traveling under remote control in response to a travel request from the remote control device and no obstacle is detected in the first speed zone.",
    "5. The materials handling vehicle according to claim 1, wherein: the controller is further configured to modify at least one vehicle parameter other than speed in response to the detection of an obstacle in at least one detection zone.",
    "6. The materials handling vehicle according to claim 5, wherein: the controller further communicates with a steer controller of the vehicle; the at least one obstacle sensor further scans at least one steer angle correction zone; and if the vehicle is traveling under remote control in response to a travel request from the remote control device, the controller is further configured to implement a steer angle correction if an obstacle is detected in a corresponding steer angle correction zone.",
    "7. The materials handling vehicle according to claim 6, wherein the controller is further configured to select a direction of steer angle adjustment based upon a determination of a position of a detected obstacle.",
    "8. The materials handling vehicle according to claim 6, wherein: the at least one steer angle correction zone comprises a plurality of different steer angle correction zones; and the controller is further configured to implement a different steer angle correction amount for each steer angle correction zone.",
    "9. The materials handling vehicle according to claim 6, wherein a steer correction angle ramp rate is editable.",
    "10. The materials handling vehicle according to claim 1, further comprising at least one presence sensor for detecting whether an operator is positioned on the vehicle, wherein the controller is further configured to operate the vehicle under remote control only when the at least one presence sensor designates that no operator is on the vehicle.",
    "11. The materials handling vehicle according to claim 1, wherein: the predetermined speed associated with the first one of the at least two speed zones comprises a first predetermined speed; the predetermined speed associated with the second one of the at least two speed zones comprises a second predetermined speed; the second speed zone is located further from the vehicle than is the first speed zone; and the second predetermined speed is greater than the first predetermined speed.",
    "12. A multiple detection zone system for a materials handling vehicle comprising: at least one contactless obstacle sensor for mounting on the vehicle, the at least one obstacle sensor operable to scan at least two speed zones, each speed zone being defined in an area at least partially in front of a forward traveling direction of the vehicle and being associated with a unique predetermined maximum speed greater than zero (0) miles per hour; and wherein: if the vehicle is traveling under remote control, a controller on the vehicle is configured to limit the vehicle speed to the predetermined maximum speed of a corresponding one of the at least two speed zones based upon the detection of an obstacle in that speed zone.",
    "13. The multiple detection zone system for a materials handling vehicle according to claim 12, wherein: the at least one obstacle sensor further scans a stop zone; and if the vehicle is traveling under remote control, the controller is further configured to implement a stop action to stop the vehicle if an obstacle is detected in the stop zone.",
    "14. The multiple detection zone system for a materials handling vehicle according to claim 13, wherein: the controller is further configured to refuse to operate the vehicle under remote control if an obstacle is detected within the stop zone before the vehicle begins travel.",
    "15. The multiple detection zone system for a materials handling vehicle according to claim 12, wherein: the predetermined speed associated with the first one of the at least two speed zones comprises a first predetermined speed; and the controller is further configured to accelerate the vehicle to a predetermined maximum speed that is greater than the first predetermined speed if the vehicle is traveling under remote control and no obstacle is detected in the first speed zone.",
    "16. The multiple detection zone system for a materials handling vehicle according to claim 12, wherein: the controller is further configured to modify at least one vehicle parameter other than speed in response to the detection of an obstacle in at least one detection zone.",
    "17. The multiple detection zone system for a materials handling vehicle according to claim 16, wherein: the controller further communicates with a steer controller of the vehicle; the at least one contactless obstacle sensor further scans at least one steer angle correction zone; and if the vehicle is traveling under remote control, the controller is further configured to implement a steer angle correction if an obstacle is detected in a corresponding steer angle correction zone.",
    "18. The multiple detection zone system for a materials handling vehicle according to claim 17, wherein the controller is further configured to select a direction of steer angle adjustment based upon a determination of a position of a detected obstacle.",
    "19. The multiple detection zone system for a materials handling vehicle according to claim 17, wherein: the at least one steer angle correction zone comprises a plurality of different steer angle correction zones; and the controller is further configured to implement a different steer angle correction amount for each steer angle correction zone.",
    "20. The multiple detection zone system for a materials handling vehicle according to claim 17, wherein a steer correction angle ramp rate is editable.",
    "21. The multiple detection zone system for a materials handling vehicle according to claim 12, further comprising at least one presence sensor for detecting whether an operator is positioned on the vehicle, wherein the controller is further configured to operate the vehicle under remote control only when the at least one presence sensor designates that no operator is on the vehicle.",
    "22. The multiple detection zone system for a materials handling vehicle according to claim 12, wherein: the predetermined speed associated with the first one of the at least two speed zones comprises a first predetermined speed; the predetermined speed associated with the second one of the at least two speed zones comprises a second predetermined speed; the second speed zone is located further from the vehicle than is the first speed zone; and the second predetermined speed is greater than the first predetermined speed.",
    "23. The multiple detection zone system for a materials handling vehicle according to claim 12, wherein the vehicle is remotely controlled via a wireless remote control device.",
    "24. A method for operating a materials handling vehicle utilizing multiple detection zones comprising: defining a first speed zone in an area at least partially in front of a forward traveling direction of the vehicle, the first speed zone being associated with a first predetermined maximum speed greater than zero (0) miles per hour; defining a second speed zone in an area at least partially in front of the forward traveling direction of the vehicle, the second speed zone being associated with a second predetermined maximum speed greater than zero (0) miles per hour and different than the first predetermined maximum speed; if the vehicle is traveling in response to the receipt of a remote travel request and an obstacle is detected in the first speed zone, limiting the speed of the vehicle to the first predetermined maximum speed; and if the vehicle is traveling in response to the receipt of a remote travel request and an obstacle is detected in the second speed zone, limiting the speed of the vehicle to the second predetermined maximum speed.",
    "25. The method according to claim 24, wherein the first and second speed zones are scanned by at least one contactless obstacle sensor on the vehicle.",
    "26. The method according to claim 24 further comprising: defining a stop zone; and if the vehicle is traveling in response to the receipt of a remote travel request and an obstacle is detected in the stop zone, implementing a stop action to stop the vehicle.",
    "27. The method according to claim 26, further comprising preventing operation of the vehicle if an obstacle is detected within the stop zone before the vehicle begins travel.",
    "28. The method according to claim 24, further comprising, if the vehicle is traveling in response to the receipt of a remote travel request, modifying at least one vehicle parameter other than speed in response to the detection of an obstacle in at least one detection zone.",
    "29. The method according to claim 28, wherein: the at least one detection zone comprises a steer angle correction zone; and modifying at least one vehicle parameter other than speed comprises implementing a steer angle correction.",
    "30. The method according to claim 29, wherein implementing a steer angle correction further comprises selecting a direction of steer angle adjustment based upon a determination of a position of a detected obstacle.",
    "31. The method according to claim 28, wherein: the at least one detection zone comprises a plurality of different steer angle correction zones; and modifying at least one vehicle parameter other than speed comprises implementing a different steer angle correction amount for each steer angle correction zone.",
    "32. The method according to claim 28, wherein a steer correction angle ramp rate is editable.",
    "33. The method according to claim 24, further comprising, if the vehicle is traveling in response to the receipt of a remote travel request, accelerating the vehicle to a predetermined maximum speed that is greater than the first predetermined speed if no obstacle is detected in the first speed zone.",
    "34. The method according to claim 24, further comprising detecting whether an operator is positioned on the vehicle, wherein the controller is further configured to operate the vehicle under remote control only when the at least one presence sensor designates that no operator is on the vehicle.",
    "35. The method according to claim 24, wherein the second speed zone is located further from the vehicle than is the first speed zone and the second predetermined speed is greater than the first predetermined speed.",
    "36. The method according to claim 24, wherein the vehicle is remotely controlled via a wireless remote control device."
  ],
  "description_excerpt": "The present invention relates in general to materials handling vehicles, and more particularly, to systems and methods that integrate detection zone information into supplemental wireless remote control arrangements for materials handling vehicles. Low level order picking trucks are commonly used for picking stock in warehouses and distribution centers. Such order picking trucks typically include load carrying forks and a power unit having a platform upon which an operator may step and ride while controlling the truck. The power unit also has a steerable wheel and corresponding traction and steering control mechanisms, e.g., a movable steering arm that is coupled to the steerable wheel. A control handle attached to the steering arm typically includes the operational controls necessary for driving the truck and operating its load handling features. In a typical stock picking operation, an operator fills orders from available stock items that are located in storage areas provided along a plurality of aisles of a warehouse or distribution center. In this regard, the operator drives a low lever order picking truck to a first location where item(s) are to be picked. In a pick process, the operator typically steps off the truck, walks over to the appropriate location and retrieves the ordered stock item(s) from their associated storage area(s). The operator then places the picked stock on a pallet, collection cage or other support structure carried by the forks of the order picking truck. Upon completing the pick process, the operator advances the order picking truck to the next location where item(s) are to be picked.",
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  "ipc": [
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  ],
  "assignees": [
    "CROWN EQUIP CORP"
  ],
  "inventors": [
    "ELSTON EDWIN R",
    "SIEFRING VERNON W",
    "JENSEN ERIC L"
  ],
  "filing_date": "2017-03-10",
  "publication_date": "2018-03-06",
  "grant_date": "2018-03-06",
  "priority_date": "2006-09-14",
  "application_number": "US-201715455571-A",
  "family_id": "42132445",
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