The present invention concerns a method for controlling the surroundings of a vehicle with at least one touchless surface sensor mounted on the vehicle as well as an apparatus for controlling the surroundings of a vehicle with a touchless surface sensor mounted on the vehicle.
Such control systems for driverless transport systems are known. Driverless transport systems are employed for transporting a variety of materials, for example raw materials for articles being worked on in factories and the like. In such systems, the transport vehicles move along predetermined paths to working stations where the vehicles are stopped for loading and unloading.
Such driverless transport systems employ control sensors. Protected areas, and their dimensions, are determined on the basis of the direction of movement of the vehicle, its speed, and the needed distance for stopping the vehicle at given speeds to develop a control protocol. The protocol is then incorporated in an overall control system for a given direction and speed range. During the operation of such a vehicle, the control protocol is activated by the actual speed of the vehicle, and the protected area is monitored for obstacles, objects and the like that may have entered it. Such a control of the surroundings of an object is disclosed in German Patent Publication 102 38 759 A1. An optoelectronic sensor on the vehicle monitors the protected area and generates data relating to the objects in the protected area. The vehicle includes a processing unit for processing data generated by the sensor. The sensed data is then fed to a downstream control unit. The control unit reacts to the received data concerning the surroundings of the vehicle in accordance with a predetermined reactive strategy by generating a corresponding control signal. The processing unit includes at least two parallel, independent evaluation paths.
An effective monitoring of the surroundings of an object is quite costly. It requires reaction strategies which properly respond to the different situations the vehicle may encounter that must be programmed in for subsequent use. In addition, the monitored information about the surroundings of the vehicle must be weighted. A control signal for controlling the vehicle is then generated in dependency on the employed reaction strategy and the applied weighting of the information concerning the surroundings of the vehicle.
Prior art control sensors for driverless transport systems are pre-programmed for operating in a number of different protected areas of the surroundings and speeds of the vehicle. When operating at a given speed, the larger protected area must be selected for maximum speed. This ordinarily results in an overly large protected area for the speed of the vehicle. This in turn leads to unnecessary vehicle stops, which can be triggered by objects in the protected area which in fact do not constitute a danger. Recognized obstacles and resulting vehicle stops significantly reduce the productivity of such systems.
On prior art driverless transport systems, the control sensors are oriented in predetermined directions which define the protected areas. All obstacles encountered in such protected areas must be evaluated for braking the vehicle, or driving it around the obstacle, even if the obstacle might not be in the actual path of the vehicle.
The installation and startup of prior art control sensors for driverless transport systems are costly. For all situations that might be encountered, such as driving the vehicle through curves or approaching an obstacle, the protected areas must be configured according to the employed reaction strategies. Typically, the routes the vehicle will take in actual use are taught and learned by the vehicle by driving it over all possible routes, which is time-consuming.
Control sensors employed by prior art transport systems store only a limited number of protected area configurations. In use, prior art monitoring systems are switched so that the accessed control information is responsive to the encountered control circumstances.
It is an object of the present invention to provide an improved method and apparatus for controlling the surroundings of a vehicle, especially a driverless transport vehicle, so that the vehicle can be controlled and collisions are avoided. Objects located in the surroundings of the vehicle are recognized by a touchless surface sensor, and data generated by the surface sensor are then used for controlling vehicle movements.
This objective is attained by employing the method for controlling the surroundings of the vehicle, especially driverless transport vehicles, for steering the vehicle. Objects in the monitored surroundings are recognized by the touchless surface sensor which generates corresponding data. The generated data is grouped into monitoring strips that are oriented parallel to the driving direction of the vehicle. Further, the speed of an object relative to the vehicle in the direction parallel to the driving direction is determined for each monitoring strip, the position of the object relative to the vehicle is determined, objects are distinguished from each other on the basis of their speeds and/or their positions, possible collisions of the vehicle with objects are calculated, and a signal is generated and transmitted to the vehicle for adjusting its speed and/or its driving direction to prevent a collision.
The present invention has the important advantage that it provides a simple method and apparatus for monitoring the surroundings of the vehicle. It is relatively simple to divide data concerning the surroundings in the driving direction into monitoring strips or sectors. The distances and speeds of the object relative to the vehicle in the individual strips are readily used for initiating a braking maneuver or for driving around the object, because each of them involves only relatively minor computations.
Since the speed vectors for the different monitoring strips of the controlled surroundings can differ, stationary objects can be distinguished from moving objects. It is even possible to determine the relative speeds of two or more objects. Thus, objects which approach the vehicle, and objects that approach the vehicle at the highest speed, can be identified. By taking the braking characteristics of the vehicle into account, the initiation of a braking maneuver can thereby be delayed to the latest possible moment for stopping or avoiding the object.
The present invention has the advantage that the vehicle can be stopped as late as possible and/or the speed of the vehicle can be optimized, which enhances the efficiency of the material transport. It is further advantageous that the vehicle's own speed need not be determined. An emergency stop is thereby delayed to the latest possible point in time.
The present invention further permits an advantageous, early reduction in the speed of the vehicle to avoid emergency stops. This is especially helpful to avoid the need for rapidly stopping the vehicle from its full travel speed when it carries goods that might sustain damage when subjected to sudden emergency stops. In addition, the flow of goods and materials is more constant and more efficient when emergency stops are avoided.
Emergency stops can also be advantageously avoided by a timely change in the travel direction of the vehicle, particularly when there is room that allows the vehicle to maneuver around obstacles. This is also helpful for driving vehicles around other stationary vehicles that are being loaded or unloaded, for example.
In one embodiment of the present invention, the vehicle surroundings are monitored with a laser scanner that periodically scans the surroundings and determines the angle and distance to an object.
It is further desirable to orient the monitoring strips so that they coincide with the direction in which the vehicle moves. In this manner, objects, which are located outside the path traveled by the vehicle, do not interrupt the travel of the vehicle.
It is advantageous to calculate the maximum permissible speed of the vehicle for preventing a collision with objects in its path while maintaining a minimum distance from the object for the speed with which the vehicle travels. Such calculation will take into account the braking characteristics of the vehicle and the type of objects that are in its path. This yields an optimal speed for the vehicle and the material transport and therefore a cost reduction as compared to conventional transport systems.
It is preferred that the optimal maximum speed of the vehicle can be continuously adjusted. This subjects the vehicle to uniform and optimal movements and reduces the wear and tear on the vehicle components.
In one preferred embodiment, the maximum permissible speed for the vehicle is cyclically sent to a communication interface for control and steering of the vehicle. In this manner, the vehicle control can continuously accelerate or decelerate the vehicle for an optimal overall speed of the vehicle.
According to another, independent invention, an actual brake characteristic for the vehicle can be established on the basis of actual decelerations encountered during a braking maneuver. By determining the actual braking characteristic, decreases in the braking ability of the vehicle can be detected. With this information, objects are more easily avoided, for example by timely driving around the objects or with an earlier initiation of the braking action.
The present invention further changes the reach of the scanner into the protected space on the basis of the actual braking characteristics of the vehicle, typically by increasing the reach. As the vehicle's braking ability deteriorates, the reach of the periodic monitoring is increased as a function of the reduction in its braking ability. This permits an earlier detection of objects.
A further aspect of the present invention provides a display and/or generates a signal that the vehicle requires service or stopping in the event a limit value of the actual braking characteristic has been exceeded. Thus, a warning signal is generated and/or displayed, especially when the braking characteristic of the vehicle drops below a predetermined limit. The signal can be used to stop the vehicle for safety reasons when its braking characteristics deviate excessively from normal, for example by deactivating the drive of the vehicle. Alternatively, the drive of the vehicle and its speed can be reduced, for example for driving the vehicle to a maintenance location for service.
The objectives of the present invention are further attained with an apparatus for monitoring the surroundings of vehicles, especially driverless transport vehicles. Such apparatus has a touchless sensor for detecting objects in the surroundings of the vehicle as well as a processor to which the data received from the surface sensor is sent. The apparatus groups data in separate monitoring strips that are parallel to the driving direction of the vehicle and includes a device for each monitoring strip which determines the relative speed of the vehicle for each monitoring strip parallel to its driving direction, a device which determines the position of the object relative to the vehicle, appropriate sensors for distinguishing between objects on the basis of their relative speed and/or position, and a device which calculates when the vehicle might collide with an object and which generates signals that are sent to the vehicle for changing its speed and/or direction to prevent a collision.
In addition, for controlling the surroundings of the vehicle, the touchless surface sensor is preferably mounted on the vehicle at a predetermined position. This allows one to take the size and dimensions of the vehicle into account when an object is recognized and enables a precise determination if, and if so when, a collision with a stationary or movable object might occur.
It is further advantageous to construct the touchless surface sensor as an optoelectronic laser scanner. This type of optoelectronic sensor is particularly suited for monitoring the surroundings of a vehicle in accordance with the present invention.
It is preferred that parameters relating to braking characteristics of the vehicle be transmitted via at least one interface. This makes it possible, for example, to download parameters which can be used with or compared to actual measured parameters of the vehicle's braking characteristics. It is equally possible to upload parameters of the actual braking characteristics via the interface for further processing or use.
The method and apparatus of the present invention are also useful for use in fields other than vehicles, for example in connection with machine tools. When used on a press brake, it can be helpful to determine the stopping time for the moving tool. In such a case, the surface sensor controls the movement of the tool. If the deceleration of the press decreases, the change in the braking characteristics of the press is detected by the surface sensor, and a signal is generated for activating a warning system and/or for deactivating the machine. In such a case, it is not necessary to group the data to parallel monitoring strips because the tools are normally of a one-piece construction and move in only one direction.
The present invention is further described in connection with practical examples and by reference to the drawings.
Laser scanner 38 is an optoelectronic sensor which has a laser light, emitting unit and a receiving unit. The emitter directs a generated laser pulse via a rotating diverter mirror into the surroundings that are to be monitored. Reflected laser impulses are received by laser scanner 38 from the surroundings and are transmitted to the receiving unit via a partially transmitting mirror. The distances to the surroundings are determined by the processor on the basis of the time elapsed between emitting a laser pulse and the receipt of the reflected light pulse. The diverter mirror is rotated with a motor. Thus, laser scanner 38 monitors the surroundings in a fan-like manner with the emitted laser pulses. The data generated thereby are processed by vehicle control unit 32 and processing unit 30. Such a laser scanner 38 is for example described in published German Patent Application DE 43 40 756 C2.
Laser scanner 38 is mounted at about the front center of the vehicle at a position 24. The position of laser scanner 38 on vehicle 2 can be varied. Laser scanner 38 can also be mounted at the corner of a vehicle 2. Mounting the scanner at the center provides the scanner with like fields of views in the lateral directions of the vehicle. Vehicle 2 has a given width 26 which depends on the nature of the materials that need to be transported and the distance between adjacent vehicle paths. Vehicle 2 moves with a given speed within the vehicle paths. Laser scanner 38 of driverless transport vehicle 46 monitors the surroundings to prevent collisions between the vehicle, path borders or persons 44.
The angular and distance information sensed by laser scanner 38 are processed by processing unit 30 with the help of appropriate software programs. This involves the transformation of coordinates and grouping the monitored data into monitoring strips 16. This is schematically shown in
This is described in more detail with reference to FIGS. 1 to 2. Vehicle 2 moves with a speed in driving direction 20 towards an object 6. For example, object 6 can be inclined relative to vehicle 2. Object 6 is shown in a first position Y′ at time t-1 and at a later, second position Y at time t. After at least one scan, the distance Y for object 6 in each monitoring strip 16 can be determined. This is illustrated in
The minimum distance “a” of object 6 is shown in
The greatest possible speed of vehicle 2 without leading to a collision is calculated on the basis of the smallest permissible distance of the object 6 and the relative speed 18 between vehicle 2 and the object. The calculation will take into consideration the braking characteristics of the vehicle. This greatest permissible speed can be relayed to the vehicle control unit 32 via a communication interface. This way the vehicle 2 can operate at the maximum permissible speed. In this manner, the efficiency of the transport system with a driverless transport vehicle 6 can be enhanced.
It is also possible to determine increasing delays in the operation of the brake system 50. For example, when an object is recognized that requires an emergency stop, the decreasing distance Y during the braking maneuver can be determined and made use of. The current braking characteristics of braking system 50 are determined by the processing unit 30 on a real-time basis and used by vehicle control 32 to establish new braking characteristics which are then used to change the manner in which the vehicle is driven, and its speeds. A decreasing effectiveness of the braking system leads to a reduction in the greatest permissible speed of vehicle 2.
As the effectiveness of braking system 50 decreases, the reach of the periodic sensing into the surroundings is changed, typically it is increased. By increasing the reach, more distant objects can be recognized and taken into consideration earlier. A decreasing effectiveness of the braking system 15 can thereby be compensated for by initiating the braking of the vehicle, or an emergency stop thereof, at an earlier point in time.
An observed change in the actual braking characteristics can also be shown, for example on a display, or a corresponding signal can be generated for further use and processing. This alerts a person responsible for the braking system 15, who then can take necessary steps such as inspecting it. When a limit value that has been set for braking characteristics is exceeded, the vehicle can be stopped out of safety consideration, or it can continue to operate but under a reduced speed.
Processing unit 30 has at least one interface for the transmittal of parameters for the braking characteristics. The parameters of the braking system 50 are sent to processing unit 30 via this interface so that they can be taken into consideration while the vehicle is in motion. Further, parameters concerning the actual, measured braking characteristics can also be transmitted via this interface. These parameters can be used, for example, by vehicle control unit 32 for further processing.
The diagrams shown in
The processing unit can distinguish wall 6 from person 4 because of the different monitored speeds and/or positions of the wall and the person. Person 44 and other objects 6 can move in different directions. For example, the person can move towards the vehicle, or it can move transversely to the driving direction of the vehicle. Person 44 can also move away from vehicle 2. The vehicle movement is corrected on the basis of how person 44 or the objects move. Process unit 30 can initiate a braking maneuver, or drive the vehicle around the obstacle, dependent on the detected motions, especially for persons which may be closer to and/or approach the vehicle at a greater speed. Since the person 44 illustrated in
The processing unit would have to initiate an emergency stop in the event person 44 enters the minimum distance 14 to vehicle 2. Beginning with the situation illustrated in
Number | Date | Country | Kind |
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102004051272.8 | Oct 2004 | DE | national |