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🔟Intelligent Safety and Positioning System Solution for Manual Forklifts
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In traditional warehousing and logistics management, manual forklifts and storage location management are core elements. However, their efficient operation is often restricted by multiple factors.
- Inefficient Route Optimization: The driving routes of manual forklifts rely on operators' experience. This not only increases the time spent on ineffective driving but also imposes a heavy workload on operators.
- Delayed Storage Location Information and Disordered Scheduling: The lack of real - time updates on storage location status leads to incorrect task assignments, reducing overall operational efficiency and even posing potential safety hazards.
- Safety Risks: In narrow aisles and high-rack environments, forklift collisions occur frequently, threatening the safety of personnel and equipment.
To address these issues, some projects have attempted to introduce positioning solutions based on UWB technology to optimize forklift routes and enhance safety. However, UWB positioning systems have shown multiple limitations in practical applications:
- Susceptible to Signal Interference: In environments with metal shelves or complex stacking, UWB signals are easily interfered with, resulting in unstable positioning data.
- Limited Precision and Single Function: The positioning accuracy of UWB is only 20 - 50 centimeters, and it can only provide location data without supporting angle information, making it difficult to meet the requirements of refined management in warehousing scenarios.
- High Deployment and Cost Pressures: In large - scale warehouses, UWB requires the installation of a large number of base stations and complex wiring, with deployment costs reaching hundreds of thousands of yuan.
- Limitations in Cargo Tracking: UWB has difficulty directly tracking the location of goods and usually needs to be combined with technologies such as RFID, further increasing system complexity and cost.
Solution
MRDVS introduces an innovative 3D vision-based intelligent solution. The system features a modular architecture, with a overhead vision 3D camera capturing ceiling and environmental features and a safety module continuously monitors surrounding obstacles.
The Manual Forklift Positioning System
The manual forklift positioning system achieves high-precision localization of 1–5 cm by mounting a 3D vision camera on top of the forklift to capture natural ceiling and wall features, representing a significant improvement compared to UWB’s 20–50 cm accuracy. At the same time, IMU-assisted positioning ensures continuous and stable localization even in environments with occlusion or insufficient visual features.
Beyond real-time positioning, the system also provides safety functions by alerting drivers to nearby personnel, vehicles, and potential hazards, while enabling the configuration of automated no-go zones. This effectively reduces the risk of collisions and other safety incidents, creating a safer environment for both operators and equipment.
MRDVS’s vision-based RTLS solution delivers higher accuracy, lower installation costs, and faster deployment compared to existing RTLS technologies such as Bluetooth and UWB, making it an ideal choice for the intelligent upgrade of manual forklifts. In addition, the positioning system can seamlessly collaborate with the storage location recognition system to enable dynamic tracking of cargo placement. By updating the status of target storage locations in real time, it prevents invalid operations and allows for flexible adjustment of task allocation and work paths.
Storage Location Recognition System
MRDVS adopts RGB-D cameras to capture both 3D spatial data and color information of storage locations, enabling automatic recognition of cargo presence, placement compliance, and abnormal occupancy. Leveraging a 3D vision AI system, the solution can also classify cargo types and output the data to the scheduling system, thereby enabling intelligent inbound and outbound warehouse operations.
Key Features
- Comprehensive Monitoring: Captures 3D spatial data and color information of storage locations, combined with AI technology for accurate status recognition.
- Easy Deployment: Algorithms run directly on the camera, eliminating the need for an external industrial computer, reducing deployment and maintenance costs.
- Flexible Communication: Supports TCP/IP, UDP, and HTTP protocols, with real-time data reporting to the control system in JSON format.
- Efficient Scheduling: Delivers real-time storage status updates to the scheduling system, enabling fast task allocation and improved operational efficiency.
Synergy of RTLS and Storage Recognition
By integrating the RTLS positioning system with the storage location recognition system, MRDVS’s solution enables unified management of forklifts, goods, and storage locations, significantly improving the accuracy and efficiency of task scheduling.
- Integrated Positioning and Recognition: The system synchronizes forklift positions with storage location status in real time, enabling dynamic cargo tracking and ensuring safe and accurate management. Seamless integration of 3D data and positioning information greatly enhances the visualization of storage conditions.
- Dynamic Task Path Adjustment: Based on real-time updates of cargo and storage status, the system flexibly adjusts forklift routes to avoid conflicts and errors, effectively reducing empty runs, improving operational efficiency, and lowering costs.
- Optimized Resource Allocation: With precise data analysis, the system maximizes the utilization of storage space and equipment, improving overall warehouse efficiency.
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