Patent Description:
In order to move items about an industrial environment, workers often utilize industrial vehicles, including for example, forklift trucks, hand and motor driven pallet trucks, and/or other materials handling vehicles. The industrial vehicles can be configured as an automated guided vehicle that navigates through the industrial environment or a manually guided vehicle that knows its location within the industrial environment. In order to facilitate automated guidance, navigation, or both, the industrial vehicle may be adapted for localization within the environment. That is the industrial vehicle can be adapted with sensors and processors for determining the location of the industrial vehicle within the environment such as, for example, pose and position of the industrial vehicle.

<CIT> discloses a speed-limit-compliance system for an industrial vehicle driven by an operator. The system includes a wireless positioning module configured for determining the location within a facility of the industrial vehicle and a speed sensor configured for determining the speed of the industrial vehicle. The system is configured to generate a speed warning when the industrial vehicle exceeds the speed limit while located within a restricted speed zone.

According to the subject matter of the present invention, and in a first aspect, a materials handling vehicle configured to navigate along an inventory transit surface in a warehouse environment comprises a speed control processor, a speed zone sensing subsystem, a materials handling mechanism configured to engage goods in the warehouse environment, a drive mechanism configured to move the materials handling vehicle along the inventory transit surface, and vehicle control architecture in communication with the drive mechanism, the materials handling mechanism, the speed zone sensing subsystem, and the speed control processor. The speed zone sensing subsystem is configured to provide an indication of whether the materials handling vehicle is in a speed zone. The speed control processor is configured to prompt a vehicle operator to reduce a vehicle speed of the materials handling vehicle to under a speed zone limit when the materials handling vehicle is approaching or in the speed zone, determine whether the vehicle speed is under the speed zone limit in the speed zone, and apply a vehicle speed cap to limit a maximum vehicle speed of the materials handling vehicle to a magnitude that is at or below the speed zone limit when the speed control processor has determined that the vehicle speed is under the speed zone limit in the speed zone.

In a second aspect, the speed zone sensing subsystem of the materials handling vehicle of the first aspect comprises one or more truck-based sensors. The speed zone sensing subsystem is configured to provide an indication of whether the materials handling vehicle is in a speed zone, and the one or more truck-based sensors are configured (i) to detect active or passive speed zone tags, (ii) for environmentally-based sensing of the speed zone, or (iii) both.

Also described is a materials handling vehicle configured to navigate along an inventory transit surface in a warehouse environment comprises an operation control processor, a restricted zone sensing subsystem, a materials handling mechanism configured to engage goods in the warehouse environment, a drive mechanism configured to move the materials handling vehicle along the inventory transit surface, and vehicle control architecture in communication with the drive mechanism, the materials handling mechanism, the restricted zone sensing subsystem, and the operation control processor. The restricted zone sensing subsystem is configured to provide an indication of whether the materials handling vehicle is in a restricted operation zone. The operation control processor is configured to prompt a vehicle operator to reduce an operation of the materials handling vehicle to under an operation limit when the materials handling vehicle speed is approaching or in the restricted operation zone, determine whether the operation is under the operation limit in the restricted operation zone, and apply an operation cap to limit a maximum operation value of the materials handling vehicle to a magnitude that is at or below the operation limit when the operation control processor has determined that the operation is under the operation limit in the restricted operation zone.

The operation control processor may be a speed control processor, the restricted zone sensing subsystem may be a speed zone sensing subsystem, the restricted operation zone may be a speed zone, the operation may be a vehicle speed, the operation limit may be a speed zone limit, and the operation cap may be a vehicle speed cap.

In a third aspect, the materials handling vehicle of the first, or second aspects, wherein the speed zone sensing subsystem comprises an operator alert component that is configured to alert the vehicle operator the materials handling vehicle is in the speed zone.

In a fourth aspect, the materials handling vehicle of the third aspect, wherein the operator alert component comprises a visual alert, an audible alert, or combinations thereof.

In a fifth aspect, the materials handling vehicle of the third aspect or the fourth aspect, wherein the operator alert component comprises a speed zone display on a display screen of the materials handling vehicle.

In a sixth aspect, the materials handling vehicle of any of the third through fifth aspects, wherein the operator alert component is further configured to alert the operator when the vehicle speed is above the speed zone limit.

In a seventh aspect, the materials handling vehicle of any of the third through sixth aspects, wherein the operator alert component is further configured to alert the operator when the vehicle speed is above the speed zone limit by an overage speed in a range of between about <NUM> mph (<NUM>/h) and <NUM> mph (<NUM>/h).

In an eighth aspect, the materials handling vehicle of the seventh aspect, wherein the overage speed is approximately <NUM> mph (<NUM>/h).

In a ninth aspect, the materials handling vehicle of any of the first through eighth aspects, wherein the speed zone sensing subsystem comprises a truck-based sensor configured to detect active or passive speed zone tags.

In a tenth aspect, the materials handling vehicle of any of the first through ninth aspects, wherein the speed zone sensing subsystem comprises a truck-based sensor configured for environmentally-based sensing of the speed zone.

In an eleventh aspect, the materials handling vehicle of any of the first through tenth aspects, wherein the speed zone sensing subsystem comprises a truck-based localization hardware configured to utilize warehouse map resident on the vehicle or an external warehouse map to sense the speed zone.

In a twelfth aspect, the materials handling vehicle of any of the first through eleventh aspects, wherein the speed zone sensing subsystem is configured to provide an indication of whether the materials handling vehicle has exited or is approaching an exit of the speed zone, and the speed control processor is configured to release the vehicle speed cap when the speed zone sensing subsystem provides the indication that the vehicle has exited or is approaching the exit of the speed zone.

In a thirteenth aspect, the materials handling vehicle of the twelfth aspect, wherein the speed zone sensing subsystem comprises an operator alert component that is configured to alert the vehicle operator when the vehicle speed cap is released, and the operator alert component comprises a visual alert, an audible alert, or combinations thereof.

In a fourteenth aspect, the materials handling vehicle of any of the first, through thirteenth aspects, wherein the speed control processor is configured to prompt the vehicle operator to reduce the vehicle speed of the materials handling vehicle to under the speed zone limit when the vehicle speed is above the speed zone limit.

In a fifteenth aspect, the materials handling vehicle of any of the first through fourteenth aspects, wherein the speed zone sensing subsystem is configured to provide an indication of whether the materials handling vehicle is in the speed zone of a plurality of speed zones in the warehouse environment, each speed zone comprising a speed zone limit from a plurality of speed zone limits, and at least one speed zone limit is different from another speed zone limit of the plurality of speed zone limits.

In a sixteenth aspect, the materials handling vehicle of any of the first through fifteenth aspects, wherein the speed control processor is configured to override the vehicle speed cap applied to the materials handling vehicle based on an operator override action, the operator override action comprising application of a throttle neutral action, application of a braking system, utilization of a dedicated override button, or combinations thereof.

The embodiments described herein generally relate to use of localization techniques to determine and assist with managing vehicle presence in speed zones in a warehouse environment as described herein. Localization is utilized herein to refer to any of a variety of system configurations that enable active tracking of a vehicle location in a warehouse, industrial or commercial facility, or other environment. For the purposes of defining and describing the concepts and scope of the present disclosure, it is noted that a "warehouse" encompasses any indoor or outdoor industrial facility in which materials handling vehicles transport goods including, but not limited to, indoor or outdoor industrial facilities that are intended primarily for the storage of goods, such as those where multi-level racks are arranged in aisles, and manufacturing facilities where goods are transported about the facility by materials handling vehicles for use in one or more manufacturing processes. The concepts of the present disclosure are not limited to any particular localization system configuration and are deemed to be applicable to any of a variety of conventional and yet-to-be developed localization systems. Such localizations systems may include those described in <CIT>, entitled LOST VEHICLE RECOVERY UTILIZING ASSOCIATED FEATURE PAIRS, and <CIT>, entitled VEHICLE POSITIONING OR NAVIGATION UTILIZING ASSOCIATED FEATURE PAIRS.

The localization systems may be used to localize and/or navigate an industrial vehicle through a warehouse environment, such as a warehouse, stock yard, or the like. In some embodiments, a camera and/or laser based system can be mounted to an industrial vehicle (e.g., automated guided vehicle or a manually guided vehicle) that navigates through a warehouse and can assist with vehicle localization. The laser based system may include a laser scanner, a laser rangefinder, a 2D/3D mapping laser, a lidar, or combinations thereof.

Referring now to <FIG>, a materials handling vehicle <NUM>, in accordance with an embodiment of the invention, is configured to navigate along an inventory transit surface <NUM> through an industrial facility such as a warehouse <NUM> in a warehouse environment <NUM>. The materials handling vehicle <NUM> comprises a drive mechanism <NUM> configured to move the materials handling vehicle <NUM> along an inventory transit surface <NUM>, a materials handling mechanism <NUM> configured to engage goods in the warehouse environment <NUM>, and vehicle control architecture in communication with the drive and materials handling mechanisms. The materials handling vehicle <NUM> also comprises a speed control processor <NUM> and a speed zone sensing subsystem <NUM>, and the vehicle control architecture is in communication with the drive mechanism <NUM>, the materials handling mechanism <NUM>, the speed zone sensing subsystem <NUM>, and the speed control processor <NUM>. The vehicle control architecture may be configured to track the navigation of the materials handling vehicle <NUM> along the inventory transit surface <NUM>, navigate the materials handling vehicle <NUM> along the inventory transit surface <NUM> in at least a partially automated manner, or both, using a localized vehicle position of the materials handling vehicle <NUM>. The materials handling vehicle <NUM> can comprise an industrial vehicle such as one for lifting and moving a payload such as, for example, a forklift truck, a reach truck, a turret truck, a walkie stacker truck, a tow tractor, a pallet truck, a high/low, a stacker-truck, trailer loader, a sideloader, a fork hoist, or the like. The industrial vehicle can be configured to automatically or manually navigate an inventory transit surface such as an inventory transit surface <NUM> of the warehouse <NUM> along a desired path. Accordingly, the materials handling vehicle <NUM> can be directed forwards and backwards by rotation of one or more wheels <NUM>. Additionally, the materials handling vehicle <NUM> can be caused to change direction by steering the one or more wheels <NUM>. Optionally, the vehicle can comprise operator controls <NUM> for controlling functions of the vehicle such as, but not limited to, the speed of the wheels <NUM>, the orientation of the wheels <NUM>, or the like. The operator controls <NUM> can comprise controls that are assigned to functions of the materials handling vehicle <NUM> such as, for example, switches, buttons, levers, handles, pedals, input/output device, or the like. It is noted that the term "navigate" as used herein means movement control or route planning of a vehicle from one place to another including, but not limited to, plotting a graphical path for a manual vehicle operation, providing a set of turn by turn instructions for manual operation, or providing an automated control guiding the vehicle along a travel path that may include such turn by turn instructions for automated operation.

The materials handling vehicle <NUM> can further comprise a localization sensor <NUM>' that may be a camera <NUM> and/or laser based system that may include a laser scanner, a laser rangefinder, a 2D/3D mapping laser, a lidar, or combinations thereof. For example, the materials handling vehicle <NUM> can further comprise a camera <NUM> as the localization sensor <NUM>' for capturing overhead images such as input images of overhead features. The camera <NUM> can be any device capable of capturing the visual appearance of an object and transforming the visual appearance into an image. In some embodiments, the materials handling vehicle <NUM> can be located within the warehouse <NUM> and be configured to capture overhead images of the ceiling <NUM> of the warehouse <NUM>.

The ceiling <NUM> of the warehouse <NUM> can comprise overhead features such as, but not limited to, ceiling lights <NUM> for providing illumination from the ceiling <NUM> or generally from above a vehicle operating in the warehouse. The ceiling lights <NUM> can comprise substantially rectangular lights such as, for example, skylights <NUM>, fluorescent lights, or the like; and may be mounted in or suspended from the ceiling or wall structures so as to provide illumination from above.

The embodiments described herein comprise one or more vehicular processors such as processors <NUM> (<FIG>) as described in greater detail below, which include a speed control processor <NUM> (<FIG>) communicatively coupled to the materials handling vehicle <NUM> along with the speed zone sensing subsystem <NUM>. The speed zone sensing subsystem <NUM> is configured to provide an indication of whether the materials handling vehicle is in a speed zone Z. In embodiments, the speed zone sensing subsystem <NUM> is configured to provide an indication of whether the materials handling vehicle <NUM> is in the speed zone Z of a plurality of speed zones in a warehouse environment, each speed zone comprising a speed zone limit from a plurality of speed zone limits, and at least one speed zone limit is different from another speed zone limit of the plurality of speed zone limits. The one or more processors <NUM> can execute machine readable instructions to implement any of the methods or functions described herein automatically. Memory <NUM> (<FIG>) for storing machine readable instructions can be communicatively coupled to the one or more processors <NUM>, the materials handling vehicle <NUM>, or any combination thereof. The one or more processors <NUM> can comprise a processor, an integrated circuit, a microchip, a computer, or any other computing device capable of executing machine readable instructions or that has been configured to execute functions in a manner analogous to machine readable instructions. The memory <NUM> can comprise RAM, ROM, a flash memory, a hard drive, or any non-transitory device capable of storing machine readable instructions.

The one or more processors <NUM> (such as the speed control processor <NUM>, the speed zone sensing subsystem <NUM>, and the controller for operator controls <NUM>) and the memory <NUM> may be integral with the materials handling vehicle <NUM>. Moreover, each of the one or more processors <NUM> and the memory <NUM> can be separated from the materials handling vehicle <NUM> and/or the camera <NUM>. For example, a management server, server, or a mobile computing device can comprise the one or more processors <NUM>, the memory <NUM>, or both. It is noted that the one or more processors <NUM>, the memory <NUM>, and the camera <NUM> may be discrete components communicatively coupled with one another without departing from the scope of the present invention. Accordingly, in some embodiments, components of the one or more processors <NUM>, components of the memory <NUM>, and components of the camera <NUM> can be physically separated from one another. The phrase "communicatively coupled," as used herein, means that components are capable of exchanging data signals with one another such as, for example, electrical signals via conductive medium, electromagnetic signals via air, optical signals via optical waveguides, or the like.

Thus, embodiments of the present disclosure may comprise logic or an algorithm written in any programming language of any generation (e.g., 1GL, 2GL, 3GL, 4GL, or 5GL). The logic or an algorithm can be written as machine language that may be directly executed by the processor, or assembly language, object-oriented programming (OOP), scripting languages, microcode, etc., that may be compiled or assembled into machine readable instructions and stored on a machine readable medium. Alternatively or additionally, the logic or algorithm may be written in a hardware description language (HDL). Further, the logic or algorithm can be implemented via either a field-programmable gate array (FPGA) configuration or an application-specific integrated circuit (ASIC), or their equivalents.

As is noted above, the materials handling vehicle <NUM> comprises or is communicatively coupled with the one or more processors <NUM>. Accordingly, the one or more processors <NUM> can execute machine readable instructions to operate or replace the function of the operator controls <NUM>. The machine readable instructions can be stored upon the memory <NUM>. Accordingly, in some embodiments, the materials handling vehicle <NUM> can be navigated automatically by the one or more processors <NUM> executing the machine readable instructions. In some embodiments, the location of the vehicle can be monitored by the localization system as the materials handling vehicle <NUM> is navigated.

For example, the materials handling vehicle <NUM> can automatically navigate along the inventory transit surface <NUM> of the warehouse <NUM> along a desired path to a desired position based upon a localized position of the materials handling vehicle <NUM>. In some embodiments, the materials handling vehicle <NUM> can determine the localized position of the materials handling vehicle <NUM> with respect to the warehouse <NUM>. The determination of the localized position of the materials handling vehicle <NUM> can be performed by comparing image data to map data. The map data can be stored locally in the memory <NUM>, which can be updated periodically, or map data provided by a server or the like. In embodiments, an industrial facility map comprises a plurality of speed zones Z of the warehouse <NUM>. Given the localized position and the desired position, a travel path can be determined for the materials handling vehicle <NUM>. Once the travel path is known, the materials handling vehicle <NUM> can travel along the travel path to navigate the inventory transit surface <NUM> of the warehouse <NUM> crossing one or more of the speed zones Z. Specifically, the one or more processors <NUM> can execute machine readable instructions to perform localization system functions and operate the materials handling vehicle <NUM>. In one embodiment, the one or more processors <NUM> can adjust the steering of the wheels <NUM> and control the throttle to cause the materials handling vehicle <NUM> to navigate the inventory transit surface <NUM>. In another embodiment, the operator may control steering of the wheels <NUM> and navigation of the materials handling vehicle <NUM> on the inventory transit surface <NUM> through use of the operator controls <NUM>. The inventory transit surface <NUM> may include one or more speed zones Z, as will be described in greater detail below.

Referring to <FIG>, the materials handling vehicle <NUM> can be configured to navigate through a warehouse environment <NUM> (<FIG>) such as the warehouse <NUM>. The industrial vehicle can be configured to automatically or manually navigate an inventory transit surface such as an inventory transit surface <NUM> of the warehouse <NUM> along a desired path.

The localization systems may be used to localize and/or navigate an industrial vehicle through a warehouse environment <NUM> (<FIG>), which may be a warehouse, stock yard, or the like. The warehouse <NUM> may include components <NUM> that may be, but are not limited to, a plurality of racks <NUM> including a plurality of shelves. In embodiments, the plurality of shelves may define a boundary of one or more aisle paths <NUM>. The aisle or portions of the aisle may be defined by at least one rack <NUM> and an opposite defining component <NUM> such as, but not limited to, one or more pallet stacks, a mezzanine, a virtually defined aisle boundary, or the like.

Referring to <FIG>, the warehouse environment <NUM>, which may be the warehouse <NUM> (<FIG>), may include a rack <NUM> and/or tag reading technology associated with path defining components <NUM> such as pallets and/or racks <NUM>. The tag reading technology may include, for example, a tag layout <NUM> in a single aisle path <NUM>, an example of which is described in <CIT> The tag layout <NUM> can be constructed to comprise individual tags, such as radio frequency identification (RFID) tags, that are positioned such that the materials handling vehicle <NUM> will operate under a defined set of vehicle functionality (e.g., vehicle function data) and/or tag-dependent position data that will endure until the materials handling vehicle <NUM> identifies another individual tag of the tag layout <NUM> with a new correlation of vehicle functionality.

In operation, the tag layout <NUM> may be utilized with respect to a tag reader and a reader module of the materials handling vehicle <NUM>, examples of which are also described in <CIT>. The reader module may include a reader memory coupled to a reader processor. The tag reader and the reader module may cooperate to identify individual tags of a tag layout <NUM>. Each individual tag of the tag layout <NUM> may correspond to a unique identification code associated with an individual tag at the beginning of the aisle path <NUM>, for example. The individual tags comprise a plurality of zone identification tags <NUM> and a plurality of zone tags <NUM>. Each zone identification tag <NUM> occupies a position in the tag layout <NUM> that corresponds to a unique set of zone tags <NUM> that each comprise a plurality of zone tags <NUM>. In one embodiment, each unique set of zone tags <NUM> comprises a plurality of zone tags <NUM>, one or more function tags <NUM>, one or more aisle extension tags <NUM>, one or more aisle entry tags <NUM>, or combinations thereof. For example, and not by way of limitation, respective zone tags <NUM> of the unique set of zone tags <NUM> that are the furthest from a midpoint <NUM> of the aisle path <NUM> may comprise both vehicle functionality and end-of-aisle vehicle functionality.

The one or more speed zones Z or <FIG> may be, for example, one or more speed zones Z1, Z2, Z3, and Z4 of <FIG>. One or more aisle paths <NUM> may comprise an in-aisle speed zone Z2 and/or an end of aisle speed zone Z3, while the warehouse environment <NUM> may include one or more out-of-aisle speed zones Z1, Z4. The speed zone Z4 may be, for example, a speed zone disposed through a door area <NUM> separating a warehouse environment section 150A from another warehouse environment section 150B. The in-aisle speed zones Z2 may be speed zones as described in <CIT>, as set forth above. As a non-limiting example, a display device of the materials handling vehicle <NUM> (<FIG>) may display "Speed Zone" and generate an audible tone or provide other alerts to indicate that the materials handling vehicle <NUM> is entering one or more speed zones Z at the current location of the materials handling vehicle <NUM> if a user is at the controls of the materials handling vehicle <NUM>, as described in greater detail below with respect to a process <NUM> (<FIG>).

As a non-limiting example, the individual tags of the tag layout <NUM> may comprise a plurality of aisle entry tags <NUM> that are positioned along an aisle path <NUM> between vehicle entry or vehicle exit portions <NUM> of the aisle path <NUM>. The reader module on the materials handling vehicle <NUM> may discriminate between the aisle entry tags <NUM> and the individual tags of the tag layout <NUM> along the aisle path <NUM> and correlate end-of-aisle vehicle functionality with an identified aisle entry tag <NUM>. A vehicle controller may control operational functions of the industrial vehicle hardware of the materials handling vehicle <NUM> in response to the correlation of end-of-aisle vehicle functionality with an identified aisle entry tag <NUM>. In this manner, a tag layout <NUM> can be constructed to comprise aisle entry tags <NUM> that are positioned within an aisle path <NUM> such that particular end-of-aisle vehicle functionality can be implemented as an industrial vehicle <NUM>, traveling within an aisle path <NUM>, approaches the vehicle entry or vehicle exit portion <NUM> of the aisle path <NUM>. An exit portion distance is a quantity of length measured between a current position of the materials handling vehicle <NUM> and the end point <NUM> of respective aisle paths <NUM>.

The reader module may discriminate between an outer end-cap tag <NUM> and an inner end-cap tag <NUM> of the end-cap pair <NUM> and correlate an identified outer end-cap tag <NUM> with exit-specific vehicle functionality and correlate an identified inner end-cap tag <NUM> with entry-specific vehicle functionality. In one embodiment, the tag layout <NUM> may comprise one or more end-cap rows <NUM> which comprise a plurality of end-cap pairs <NUM>. The one or more end-cap rows <NUM> are spaced across respective end points <NUM> of an aisle path <NUM> such that an industrial vehicle entering or exiting the aisle path <NUM> will identify the individual tags of the end-cap row <NUM> regardless of where the materials handling vehicle <NUM> crosses the end-cap row <NUM> within the vehicle entry or vehicle exit portion <NUM> of the aisle path <NUM>. The rack <NUM> may be a multilevel rack in defining a portion of the aisle path <NUM> in a very narrow aisle (VNA) warehouse.

Referring to <FIG>, the embodiments described herein can comprise a system <NUM> including one or more vehicular processors such as processors <NUM> such as the speed control processor <NUM> and vehicle control architecture that may be communicatively coupled to a memory <NUM>. A network interface hardware <NUM> may facilitate communications over a network <NUM> via wires, a wide area network, a local area network, a personal area network, a cellular network, a satellite network, and the like. Suitable personal area networks may include wireless technologies such as, for example, IrDA, Bluetooth, Wireless USB, Z-Wave, ZigBee, and/or other near field communication protocols. Suitable personal area networks may similarly include wired computer buses such as, for example, USB and FireWire. Suitable cellular networks include, but are not limited to, technologies such as LTE, WiMAX, UMTS, CDMA, and GSM. The network interface hardware <NUM> can be communicatively coupled to any device capable of transmitting and/or receiving data via the network <NUM>. Accordingly, the network interface hardware <NUM> can include a communication transceiver for sending and/or receiving any wired or wireless communication. For example, the network interface hardware <NUM> may include an antenna, a modem, LAN port, Wi-Fi card, WiMax card, mobile communications hardware, near-field communication hardware, satellite communication hardware and/or any wired or wireless hardware for communicating with other networks and/or devices.

The one or more processors <NUM> can execute machine readable instructions to implement any of the methods or functions described herein automatically. Memory <NUM> as at least one of non-volatile memory <NUM> or volatile memory <NUM> in a computer readable medium <NUM> for storing machine readable instructions can be communicatively coupled to the one or more processors <NUM>. The one or more processors <NUM> can comprise a processor, an integrated circuit, a microchip, a computer, or any other computing device capable of executing machine readable instructions or that has been configured to execute functions in a manner analogous to machine readable instructions. The computer readable medium <NUM> can comprise RAM, ROM, a flash memory, a hard drive, or any non-transitory device capable of storing machine readable instructions.

Each of the one or more processors <NUM> and the memory <NUM> can be integral with the materials handling vehicle <NUM>. Moreover, each of the one or more processors <NUM> and the memory <NUM> can be separated from the materials handling vehicle <NUM>. For example, a management server, server, or a mobile computing device can comprise the one or more processors <NUM>, the memory <NUM>, or both. It is noted that the one or more processors <NUM> and the memory <NUM> may be discrete components communicatively coupled with one another without departing from the scope of the present invention. Accordingly, in some embodiments, components of the one or more processors <NUM> and components of the memory <NUM> can be physically separated from one another. The phrase "communicatively coupled," as used herein, means that components are capable of exchanging data signals with one another such as, for example, electrical signals via conductive medium, electromagnetic signals via air, optical signals via optical waveguides, or the like.

Thus, embodiments of the present disclosure may comprise logic or an algorithm written in any programming language of any generation (e.g., 1GL, 2GL, 3GL, 4GL, or 5GL). The logic or an algorithm can be written as machine language that may be directly executed by the processor, or assembly language, object-oriented programming (OOP), scripting languages, microcode, etc., that may be compiled or assembled into machine readable instructions and stored on a machine readable medium such as computer readable medium <NUM>. Alternatively or additionally, the logic or algorithm may be written in a hardware description language (HDL). Further, the logic or algorithm can be implemented via either a field-programmable gate array (FPGA) configuration or an application-specific integrated circuit (ASIC), or their equivalents.

In embodiments, one or more warehouse maps <NUM> of the warehouse environment <NUM> (<FIG>) associated with a database <NUM> comprising one or more speed zone locations Z1-Z4 in the warehouse environment <NUM> may be stored in the memory <NUM>. The system <NUM> can include one or more displays and/or output devices <NUM> such as monitors, speakers, headphones, projectors, wearable-displays, holographic displays, and/or printers, for example. Output devices <NUM> may be configured to output audio, visual, and/or tactile signals and may further include, for example, audio speakers, devices that emit energy (radio, microwave, infrared, visible light, ultraviolet, x-ray and gamma ray), electronic output devices (Wi-Fi, radar, laser, etc.), audio (of any frequency), etc..

The system <NUM> may further include one or more input devices <NUM> which can include, by way of example, any type of mouse, keyboard, disk/media drive, memory stick/thumb-drive, memory card, pen, touch-input device, biometric scanner, voice/auditory input device, motion-detector, camera, scale, and the like. Input devices <NUM> may further include cameras, such as digital and/or analog cameras, still cameras, video cameras, thermal imaging cameras, infrared cameras, cameras with a charge-couple display, night-vision cameras, three dimensional cameras, webcams, audio recorders, a laser scanner, a laser rangefinder, a 2D/3D mapping laser, a lidar, and the like. For example, an input device <NUM> may include the localization sensor <NUM>' such as the camera <NUM> described herein.

As is noted above, the materials handling vehicle <NUM> can comprise or be communicatively coupled with the one or more processors <NUM>. Accordingly, the one or more processors <NUM> can execute machine readable instructions to operate or replace the function of the operator controls. The machine readable instructions can be stored upon the memory <NUM>, <NUM>. Accordingly, in some embodiments, the materials handling vehicle <NUM> can be navigated automatically by the one or more processors <NUM> executing the machine readable instructions. In some embodiments, the location of the materials handling vehicle <NUM> can be monitored by the localization system as the materials handling vehicle <NUM> is navigated.

For example, the materials handling vehicle <NUM> can automatically or manually navigate along the inventory transit surface <NUM> of the warehouse <NUM> along a desired path to a desired position based upon a localized position of the materials handling vehicle <NUM>. In some embodiments, the materials handling vehicle <NUM> can determine the localized position of the materials handling vehicle <NUM> with respect to the warehouse <NUM>. The determination of the localized position of the materials handling vehicle <NUM> can be performed by comparing data from the localization sensor <NUM>' to map data. In an embodiment, the data from the localization sensor <NUM>' as the camera <NUM> may be image data. The map data can be stored locally in the memory <NUM> as one or more warehouse maps <NUM>, which can be updated periodically, or map data provided by a server or the like. In embodiments, an industrial facility map comprises a mapping of the one or more speed zones Z, Z1, Z2, Z3, and Z4 as stored in the database <NUM> as described herein. Specifically, the one or more processors <NUM> can execute machine readable instructions to perform localization system functions and operate or assist with operation of the materials handling vehicle <NUM>.

In an embodiment, mapping of the one or more speed zones Z, Z1, Z2, Z3, and Z4 may occur through manual mapping utilizing a laser tool such as a laser range finder or laser distance meter or other suitable mapping scanning tools. In embodiments, utilized individual tags, such as RFID tags as described herein, may be mapped utilizing same or similar techniques while further using an antenna to identify a location of the individual tag.

Referring to <FIG>, the system <NUM> is configured to implement a process <NUM>. As a non-limiting example, the process <NUM> may be a control scheme to determine through the one or more processors <NUM> following machine-readable instructions, and through localization techniques as described herein, for example, a location of the materials handling vehicle <NUM> in the warehouse environment <NUM> to determine a current localized position of the materials handling vehicle <NUM> in the warehouse environment <NUM>. The speed zone sensing subsystem <NUM> that is configured to provide an indication of whether the materials handling vehicle <NUM> is in a speed zone may use the current localized position in comparison to stored and/or sensed speed zone locations to make this determination.

Thus, in an aspect, the process <NUM> determines whether the materials handling vehicle <NUM> is in a speed zone Z based on the current localized position. As a non-limiting example, a navigation subsystem of the materials handling vehicle <NUM> may comprise one or more environmental sensors and an environmental database. In embodiments, the environmental sensors are configured to capture data indicative of a position of the materials handling vehicle <NUM> relative to the inventory transit surface <NUM> in the warehouse <NUM>. Further, the environmental database may reside on or be remote from the materials handling vehicle <NUM> and may comprise stored data indicative of the one or more speed zones Z, Z1, Z2, Z3, and Z4, the inventory transit surface <NUM>, or both. The navigation subsystem may be configured to enable at least partially automated navigation of the materials handling vehicle <NUM> along the inventory transit surface <NUM> utilizing the captured data and the stored data. For example, and not by way of limitation, it is contemplated that the navigation subsystem, the localization system, or both may utilize a stored warehouse map <NUM> and captured images of ceiling lights <NUM> or skylights <NUM> to enable navigation, localization, or both, as is disclosed in <CIT>, (CRNZ <NUM> PA), <CIT> (docket no. CRNZ <NUM> NA), <CIT> (docket no. CRNZ <NUM> PA), <CIT> (docket no. INRO <NUM> NA), and other similar patents and patent publications. It is further contemplated that the navigation subsystem, a localization subsystem, or both may utilize a stored warehouse map <NUM> and a tag layout <NUM> disposed on the inventory transit surface <NUM> as disclosed in <CIT> (CRO <NUM> PA), and other similar patents and patent publications. Additional suitable environmental sensors include, but are not limited to, inertial sensors, lasers, antennae for reading RFID tags, buried wires, WiFi signals, or radio signals, global positioning system (GPS) sensors, global navigation satellite system (GNSS) sensors, ultra-wideband (UWB) sensors, or combinations thereof. By way of example and not as a limitation, UWB technology may be utilized for localization. UWB technology is a radio technology utilizing a low energy level for short-range, high-bandwidth communication over an ultra-wide radio spectrum portion, such as <NUM> to <NUM>. UWB technology may include a transmitter on the materials handling vehicle <NUM> configured to transmit UWB transmissions for receipt by a receiver-anchor disposed in the warehouse environment <NUM>. Such UWB transmissions generate radio energy at specific time intervals while occupying a large bandwidth at low energy levels and enable pulse-position or time modulation, and may modulate transmitted information on UWB pulse signals. An ability for the UWB technology to determine a time of flight of the transmission at different frequencies may assist with measuring distances at a high resolution and accuracy for localization. In an embodiment, such UWB technology may be utilized for localization as a backup to another current localization system to provide sufficient system redundancy and system self-checks in a manner that achieves a safety level required for automatic control of the materials handling vehicle <NUM>.

In block <NUM>, the vehicle operator is prompted to reduce a vehicle speed of the materials handling vehicle <NUM> to under a speed zone limit when the materials handling vehicle is approaching or in the speed zone Z. The materials handling vehicle <NUM> may be considered to be "in" the speed zone Z as described herein when the materials handling vehicle <NUM> is partially or fully in the speed zone z. The materials handling vehicle <NUM> can be considered to be "approaching" a speed zone Z when the speed zone sensing subsystem <NUM> has detected the presence of the speed zone Z and the operating conditions of the materials handling vehicle <NUM> represent an operating condition where it is more likely than not that the materials handling vehicle <NUM> will actually enter the speed zone Z. Further, the speed control processor <NUM> may be configured to prompt the vehicle operator to reduce the vehicle speed of the materials handling vehicle <NUM> to under the speed zone limit when the vehicle speed is above the speed zone limit. The speed zone sensing subsystem <NUM> may include an operator alert component that is configured to alert the vehicle operator when the vehicle speed is above the speed zone limit, and the operator alert component may include a visual alert, an audible alert, or combinations thereof. By way of example, and not as a limitation, the visual alert may include a display on a display screen of the materials handling vehicle <NUM>, and the audible alert may include an audible tone. When the vehicle speed is above the speed zone limit, the display for the visual alert may include a red display screen, a flashing display screen, a negative shape on the display, verbiage indicating speed overage, or combinations thereof. The negative shape on the display may include an X, N, minus sign, or exclamation point. The audible alert may include a negative audible tone, which may include a high decibel sound provided by a horn for a period of time corresponding to an overage period in which the vehicle speed is above the speed zone limit.

In embodiments, the process <NUM> alerts the vehicle operator that the materials handling vehicle <NUM> is in the speed zone Z. The speed zone sensing subsystem <NUM> may include an operator alert component that is configured to alert the vehicle operator the materials handling vehicle <NUM> is in the speed zone Z. The operator alert component may include a visual alert, an audible alert, a speed zone display on a display screen of the materials handling vehicle, or combinations thereof. Additionally or alternatively, the operator alert component may be configured to alert the operator when the vehicle speed is above the speed zone limit. As a non-limiting example, the operator alert component may be configured to alert the operator when the vehicle speed is above the speed zone limit by an overage speed in a range of between about <NUM> mph (<NUM>/h) and <NUM> mph (<NUM>/h), such as when the overage speed is approximately <NUM> mph (<NUM>/h).

As a non-limiting example, the operator may be prompted through display screen alerts and/or audible tone based alerts that the materials handling vehicle <NUM> is entering the speed zone Z. Further, an alert may indicate to the operator that the vehicle is over the speed limit. In an embodiment, an alert such as a red display screen of a display screen of the materials handling vehicle <NUM> and/or a negative tone may indicate to the operator that the vehicle is over the speed limit by a threshold which may be approximately <NUM> mph (<NUM>/h) over the speed limit. Additionally or alternatively, the display screen may be flashing to indicate vehicle speeding in the speed zone Z, may use a different color, or may use a negative shape such as X or N or a minus sign or exclamation point. The negative tone may be a high decibel sound such as one provided by a horn, for instance, and may be provided for a period of time such as <NUM> seconds, during intervals, or over a duration of the speed overage period. The display screen may additionally or alternatively display verbiage indicating that the materials handling vehicle <NUM> is over the speed limit associated with the speed zone Z while in the speed zone Z. The process <NUM> further alerts and prompts the vehicle operator to reduce vehicle speed of the materials handling vehicle <NUM> to under a speed zone limit when the materials handling vehicle <NUM> is in the speed zone Z, Z1, Z2, Z3, and/or Z4. By way of example, and not as a limitation, each speed zone Z, Z1, Z2, Z3, and Z4 may include a respective speed zone limit different from the other speed zone limits. Further, each speed zone Z, Z1, Z2, Z3 may include other limits such as lift height restrictions and the like. In an embodiment, one or more performance settings of the materials handling vehicle <NUM> may be adjusted and/or restricted to limit speed of the materials handling vehicle <NUM>, such as slowing of an acceleration profile and/or lifting profile of the materials handling vehicle <NUM>, which may assist to increase safety of the materials handling vehicle <NUM> in a high traffic areas, for instance. Similar restrictions may be imposed with respect to the speed zones Z, Z1, Z2, Z3, and /or Z4 as set forth in <CIT> (CRO <NUM> PA), and other similar patents and patent publications.

The speed zone sensing subsystem <NUM> may include one or more truck-based sensors. A truck sensor of the one or more truck-based sensors may be configured to detect active or passive speed zone tags <NUM>. A truck sensor of the one or more truck-based sensors may be configured for environmentally-based sensing of the speed zone Z. The one or more truck-based sensors may be configured to detect active or passive speed zone tags <NUM>, for environmentally-based sensing of the speed zone Z, or combinations thereof. In embodiments, the speed zone sensing subsystem <NUM> may include truck-based localization hardware configured to utilize warehouse map resident on the vehicle or an external warehouse map to sense the speed zone Z to then provide the indication of whether the materials handling vehicle <NUM> is in the speed zone Z.

In block <NUM>, the process <NUM>, through the speed control processor <NUM>, determines whether the vehicle speed is under the speed zone limit in the speed zone Z. Upon a positive determination, the process may proceed to block <NUM>.

In block <NUM>, a vehicle speed cap is applied to limit a maximum vehicle speed of the materials handling vehicle to a magnitude that is at or below the speed zone limit when the speed control processor has determined that the vehicle speed is under the speed zone limit in the speed zone. In this manner, by waiting for the vehicle speed to drop below the speed zone limit in this speed zone Z, the speed control technology of the present disclosure allows the operator of the vehicle to actively or passively contribute to the speed cap application process. In many cases, this will provide for a more gradual and operator-friendly reduction in vehicle speed when the vehicle enters the speed zone Z. The process <NUM> may thus use the speed control processor <NUM> to apply a vehicle speed cap to the materials handling vehicle <NUM> at the speed zone limit within the speed zone based on a speed reduction by the operator in the speed zone Z. The alert to the vehicle operator that the materials handling vehicle <NUM> is in the speed zone Z may result in the operator reducing the speed of the materials handling vehicle <NUM>, such as when the materials handling vehicle <NUM> is operating at above the speed zone limit, such that the operator controls the reduction of the speed of the materials handling vehicle <NUM>. Once the speed of the materials handling vehicle <NUM> is reduced to be operating within the speed zone limit, the vehicle speed cap is applied to the materials handling vehicle <NUM> in block <NUM>. Through such selective application of a vehicle speed cap based on a speed reduction by the operator in the speed zone Z, the operator is able to maintain a speed at or under the speed limit and not risk one or more operator distractions that may result through, for example, watching the display screen of the vehicle while otherwise trying to maintain an uncapped speed in the speed zone Z. Such a selective application may thus encourage safe operator habits over an operator reliance of automated vehicle override of operator control with respect to vehicle speed when entering a speed zone as the operator may maintain control of the vehicle speed upon speed zone entry.

Other parameters than speed that may be maintained at a cap while in the speed zone may additionally be, as non-limiting examples, lift acceleration, lift speed, and/or vehicle acceleration that may be limited or capped with respect to certain pre-defined areas of the warehouse environment <NUM> such as the warehouse <NUM>. Thus, the speed control processor <NUM> may rather act as an operation control processor, and the speed zone sensing subsystem <NUM> may act as restricted zone sensing subsystem. The operation control processor may then be configured to prompt the vehicle operator to reduce an operation of the materials handling vehicle <NUM> to under an operation limit when the materials handling vehicle is approaching or in the restricted operation zone, determine whether the operation is under the operation limit in the restricted operation zone, and apply an operation cap to limit a maximum operation value of the materials handling vehicle <NUM> to a magnitude that is at or below the operation limit when the operation control processor has determined that the operation is under the operation limit in the restricted operation zone. As described above with respect to process <NUM>, the restricted operation zone may be a speed zone Z, the operation may be a vehicle speed, the operation limit may be a speed zone limit, and the operation cap may be a vehicle speed cap. Additionally or alternatively, the operation may be a vehicle acceleration, a lift height, a lift speed, and/or a lift acceleration. The operation limit may then respectively be a vehicle acceleration limit, a lift height restriction, a lift speed limit, or a lift acceleration limit, and the operation cap may respectively be a vehicle acceleration cap, a lift height cap, a lift speed cap, or a lift acceleration cap.

In an embodiment, the operation control processor may be configured to override the operation cap applied to the materials handling vehicle <NUM> at the operation limit within the restricted operation zone based on an operator override action. The operator override action may include application of a throttle neutral action, application of a braking system, utilization of a dedicated override button, or combinations thereof.

In an aspect, the speed cap may be overridden by the operator. By way of example and not as a limitation, the operator may initiate an override operation through application of a throttle neutral action to release the speed cap. Alternatively, the override operation may include application of a braking system to brake the materials handling vehicle <NUM> and come to a complete stop or utilization of a dedicated override button to override the speed cap application. In an embodiment in which an erroneous prompt may be made outside of a speed zone Z and a speed cap applied, such as where a vehicle may become lost, the speed cap may be maintained until the vehicle position is recovered or the operator may override the speed cap through the override operation. In an aspect, the speed control processor <NUM> is configured to override the vehicle speed cap applied to the materials handling vehicle <NUM> based on the operator override action as described herein.

The speed zone sensing subsystem <NUM> may be configured to provide an indication of whether the materials handling vehicle <NUM> has exited or is approaching an exit of the speed zone Z. The speed control processor <NUM> may be configured to release the vehicle speed cap when the speed zone sensing subsystem <NUM> provides the indication that the vehicle has exited or is approaching an exit of the speed zone Z. The speed zone sensing subsystem <NUM> may include an operator alert component that is configured to alert the vehicle operator when the vehicle speed cap is released. The operator alert component may include a visual alert, an audible alert, or combinations thereof, as described herein.

In an embodiment, a positive green display screen and a positive tone may indicate to the operator that the operator is exiting the zone without a speed violation. The positive tone may be a light, low decibel based tone such as a bell ding. Additionally or alternatively, the display screen may use a different color, or may use a positive shape such as Y, a check mark, or a plus sign. Further, when the materials handling vehicle <NUM> exits the speed zone Z, the process <NUM> may automatically release the speed cap and provide the operator with at least one of a visual alert and audible indication that the speed cap is released and the materials handling vehicle <NUM> is exiting the speed zone Z. Thus, the operator will not need a throttle natural action to release the speed cap as this release may be automatically performed.

Such speed management applications with respect to the materials handling vehicle <NUM> and one or more speed zones Z, Z1, Z2 in a warehouse environment <NUM> as described herein provide a driver assistance function to prevent operator distraction while maintaining a speed limit in the speed zone Z, Z1, Z2. Further, use of a tag layout <NUM> associated with vehicle localization and/or speed zone mapping as described herein may occur such as through use of a row of RFID tags around a perimeter of a speed zone Z, Z1, Z2. The speed management applications as described herein are suitable for in-aisle, out-of-aisle, large area speed zone, and other warehouse environment area applications. Interaction logic providing by the process <NUM> and the embodiments described herein directed to alerting the operator of a materials handling vehicle <NUM> to slow down in a speed zone Z, Z1, Z2 without an automatic braking through a system of the materials handling vehicle <NUM>, and subsequent application of a speed cap associated with the speed zone Z, Z1, Z2, when the operator reduces the speed of the materials handling vehicle <NUM> to be under the speed zone limit assists the operator in maintaining a safe and efficient speed in the speed zone Z, Z1, and Z2 without adding to and rather preventing against operator distraction during such speed maintenance.

For the purposes of describing and defining the present disclosure, it is noted that reference herein to a variable being a "function" of or "based on" a parameter or another variable is not intended to denote that the variable is exclusively a function of or "based on" the listed parameter or variable. Rather, reference herein to a variable that is a "function" of or "based on" a listed parameter is intended to be open ended such that the variable may be a function of a single parameter or a plurality of parameters.

It is also noted that recitations herein of "at least one" component, element, etc., should not be used to create an inference that the alternative use of the articles "a" or "an" should be limited to a single component, element, etc..

It is noted that recitations herein of a component of the present disclosure being "configured" or "programmed" in a particular way, to embody a particular property, or to function in a particular manner, are structural recitations, as opposed to recitations of intended use. More specifically, the references herein to the manner in which a component is "configured" or "programmed" denotes an existing physical condition of the component and, as such, is to be taken as a definite recitation of the structural characteristics of the component.

Claim 1:
A materials handling vehicle (<NUM>) configured to navigate along an inventory transit surface (<NUM>) in a warehouse environment (<NUM>), the materials handling vehicle (<NUM>) comprising
a speed control processor (<NUM>),
a speed zone sensing subsystem (<NUM>),
a materials handling mechanism (<NUM>) configured to engage goods in the warehouse environment (<NUM>),
a drive mechanism (<NUM>) configured to move the materials handling vehicle (<NUM>) along the inventory transit surface (<NUM>), and
vehicle control architecture in communication with the drive mechanism (<NUM>), the materials handling mechanism (<NUM>), the speed zone sensing subsystem (<NUM>), and the speed control processor (<NUM>), wherein:
the speed zone sensing subsystem (<NUM>) is configured to provide an indication of whether the materials handling vehicle (<NUM>) is in a speed zone (Z);
the speed control processor (<NUM>) is configured to
prompt a vehicle operator to reduce a vehicle speed of the materials handling vehicle (<NUM>) to under a speed zone limit when the materials handling vehicle (<NUM>) is approaching or in the speed zone (Z),
determine whether the vehicle speed is under the speed zone limit in the speed zone (Z), and characterised in that the speed control processor is further configured to:
apply a vehicle speed cap to limit a maximum vehicle speed of the materials handling vehicle (<NUM>) to a magnitude that is at or below the speed zone limit when the speed control processor (<NUM>) has determined that the vehicle speed is under the speed zone limit in the speed zone (Z).