WO2017155488A1

WO2017155488A1 - A forklift training simulator system

Info

Publication number: WO2017155488A1
Application number: PCT/TR2016/050427
Authority: WO
Inventors: Ayse KAYHAN; Mustafa Metin SENGEL
Original assignee: Still Arser Is Makinalari Servis Ve Ticaret Anonim Sirketi
Priority date: 2016-03-11
Filing date: 2016-11-04
Publication date: 2017-09-14

Abstract

The invention relates to a forklift training simulator system for improving awareness for occupational safety and making and testing occupational safety trainings in real-like scenarios, analyzing operator habits, allowing them to see the possible accidents they might encounter and raise awareness before having the accident, and performing exams in real situations and on real devices.

Description

DESCRIPTION

A Forklift Training Simulator System The Related Art

The invention relates to improving awareness for occupational safety and making and testing occupational safety trainings in real-like scenarios, analyzing operator habits, allowing them to see the possible accidents they might encounter and raise awareness before having the accident, performing exams in real situations and on real devices, and forming logistic (shelf arrangement etc.) system in factory and showing the users the final way of usage, and allowing one-to-one testing. The invention particularly relates to a forklift designed to be used as mobile training center for vocational high schools, colleges, universities, and operator driver courses, by using real equipment and to provide its own energy via the solar energy panels found thereon. The Prior Art

Nowadays, simulators that look like forklifts are used for instructional purposes for training operators. However, since there is no environment to test operators after they have their operator's licenses, performances of said operators cannot be evaluated and their operator skills cannot be tested.

In the prior art applications, a real-like or close-to-real forklift simulator is not found. Furthermore, since forklift simulators are fixed and not mobile in the prior art applications, said forklift simulator application cannot be transported to desired locations. In many vocational high schools and colleges that provide forklift courses, people who take forklift courses graduate without even seeing a forklift and having the testing experience on a forklift. As a result, forklift operators do not recognize the occupational safety equipment found on forklifts and this leads to accidents, since they do not use said occupational safety equipment.

The application with no. CN203444662, encountered as a result of technical research relates to the operating principle of forklifts and improving the usage experience of said forklifts. In another application with no. DE41 14103 encountered as a result of technical research, the forklift simulator is made for the purpose of making the overturning movement detectable.

In another application with no. US5078608 encountered as a result of technical research, the forklift simulator is made for testing operators for training purpose. However, the method of reporting the test results of said forklift simulator and the way of education activities in different areas are not disclosed.

As a result, the above said drawbacks and the inadequacy of the prior art solutions about the subject have necessitated an improvement in the related technical field.

Purpose of the Invention The invention is formed with the inspiration from the prior art situations and aims to solve the above said problems.

The main purpose of the invention is to provide and test occupational safety trainings with real-like or close-to-real scenarios.

Another purpose of the invention is to provide occupational safety and operator training and aim gaining experience in the virtual environment to be created. In order to minimize occupational accidents, forklift operators will be placed in accident situations in scenarios that will lead to accidents, so as to raise their awareness. In this way, said operators will see the outcomes of their mistakes and gain experience in virtual environment without the risk of a real danger.

Another purpose of the invention is to analyze the usage habits of forklift operators and record their test results in the system and provide written report or send e-mail to relevant people. Another purpose of the invention is to allow forklift operators to see the possible accidents they might encounter and raise their awareness before they experience these accidents.

Another purpose of the invention is to provide technical training visually on a real forklift.

Another purpose of the invention is to improve usage abilities of forklift operators on different machine models, provide them with practical experience, and install different machine model software on the forklift simulator.

Another purpose of the invention is to introduce products to new customers by using forklift simulators as a marketing activity.

Another purpose of the invention is to raise awareness of forklift operators by visually introducing the occupational safety equipment found on the forklift and showing the operators how they work.

Another purpose of the invention is to design forklift simulators as mobile training centers for use by vocational high schools, colleges, universities, and operator driver courses. Another purpose of the invention is to test the education level and give score to forklift operators so as to raise their awareness and determine their mistakes.

Another purpose of the invention is to simulate possible accidents that forklift operators may encounter and show the operators the reasons of these accidents.

Another purpose of the invention is to show forklift operators the possible accidents that may occur when the occupational safety equipment found on the forklift is not used.

Another purpose of the invention is to use a scrap forklift and ensure its recycle, and in this way, provide a real forklift usage experience to the user, since all the equipments found on the forklift simulator are original.

Another purpose of the invention is to provide a one-to-one study with the factory field in virtual environment about the factory logistic operations (such as shelf system operations according to factory needs), and enable the users to test said one-to-one operation, and thus prevent high costs in these kind of big investments.

Another purpose of the invention is to prevent loss of labour, time, and money in training and marketing activities. Another purpose of the invention is to arrange forklift simulators so as to generate their own energy via solar energy panels and in this way allow them to be mobile.

Another purpose of the invention is to ensure that the forklift simulator operates in an integrated manner with the monitoring and battery system and perform online analysis of the characteristics of the person who will use said forklift simulator via operator driving characteristics (harsh use, accident, battery use etc.).

Another purpose of the invention is to arrange the forklift simulator such that all the details would be recorded by the camera during the training and photos would be taken when desired.

Another purpose of the invention is to use the simulator system according to the invention with the purpose of improving occupational safety in factories.

Another purpose of the invention is to allow monitoring of the operator from an external display screen by means of an external camera while he/she uses the simulator, record the operator behaviours during the simulation, and allow the operator to watch himself/herself later on.

Another purpose of the invention is to ensure that photos of people who attend the simulation are printed out by means of a printer and given them as a souvenir. In order to achieve the above said purposes, the invention is a forklift training simulator system allowing an operator to enter into a simulator cabin and move within a simulation scenario, and it is characterized in that; it comprises:

• control systems found on the simulator and controlled by the operator according to the simulation scenario,

• electronic control card 1 , which is connected to said control systems and thus transfers the information received from the control systems to the simulator computer, and turns the status control LEDs on or off according to the activity situation of the control systems,

· a simulation software installed simulator computer, which allows transfer of simulation visuals to display screens, communicates with the instructor computer and tablet by means of a wireless network device, and controlling the simulator in accordance with the control systems information received from electronic control card 1 ,

• a wireless network device providing wireless network communication between a tablet, a simulator computer, and an instructor computer found on the same network,

• an instructor computer transmitting the images and commands by communicating with the simulator software found on the simulator computer and allowing remote control of the forklift training simulator system,

• a tablet allowing control of the forklift training simulator system, transmitting the images and commands by communicating with the simulator software found on the simulator computer by means of the wireless network device, and mounted on the indicator panel found within the simulator cabin.

The structural and characteristic features of the invention and all of its advantages shall be understood better with the figures and the detailed description given below in reference to the figures, and therefore, the assessment should be made by taking into account the said figures and detailed explanations.

Figures for Better Understanding of the Invention

Figure 1 is a two-dimensional detailed view of a preferred embodiment of the forklift training simulator system according to the invention.

Figure 2 is a two-dimensional side view of a preferred embodiment of the TV system of a forklift training simulator system according to the invention.

Figure 3 is a two-dimensional top view of a preferred embodiment of the TV system of a forklift training simulator system according to the invention.

Figure 4 is a block diagram of a forklift training simulator system according to the invention. Description of Parts References

A. Speakers

B. Control systems

C. Status control LEDs D. Screens

1 . Steering wheel

2. Beacon lamp control

3. Seat switch

4. Seatbelt switch

5. Instructor computer

6. Electronic control card 1

7. Beacon lamp

8. Card reader

9. Wireless network device l O.Tablet

1 1 . Indicator panel

12. Left screen

13. Right screen

14. Front screen

15. Rear screen

16. Central speaker

17. Rear left speaker

18. Rear right speaker

19. Front left speaker

20. Front right speaker 21 .Subwoofer

22. Simulator computer 23. Computer camera

24. Wireless keyboard/mouse

25. Photograph printer

26. External screen 27. Electronic control card 2

28. Vibration motor

29. Power distribution panel

30. Steering wheel counter

LED: Light Emitted Diode

Drawings do not have to be scaled and details not necessary for understanding the present invention may be neglected. Moreover, components which are at least widely equal or which have at least widely equal functions are shown with the same number.

Detailed Description of the Invention In this detailed description, the preferred embodiments of a forklift training simulator system according to the present invention, will only be disclosed for better understanding of the subject.

Simulator electronic control card 1 (6), electronic control card 2 (27), and screens (D) are mounted to a real simulator so as to provide a real simulator experience. Said screens (D) are a front screen (14), a rear screen (15), a right screen (13), and a left screen (12). Visual presentation is provided by means of the 60 inch left screen (12), right screen (13), and front screen (14) that are positioned vertically outside the cabin and the 60 inch rear screen (15) that is positioned horizontally at the back of said cabin.

A forklift training simulator system according to the invention can either be controlled by means of a tablet (10) that is mounted on the indicator panel (1 1 ) or by an instructor using an instructor computer (5) found on the network. The information of the forklift operator using the simulator are recorded by means of a card reader (8) (preferably mifare). Said card reader (8) also records harsh use and accident information by associating to said operator. The wireless network communication is ensured between the tablet (10), simulator computer (22), and instructor computer (5) via wireless network device (9).

Forklift simulator controls;

All the control systems (B) found on the forklift will be in interaction with the simulator. On the panel where the steering wheel (1 ) is found, said control system (B) comprises:

• an ignition switch turning the simulator on and off by means of a key or a card reader (8),

• a steering wheel counter (30), which calculates the rotational movements of the steering wheel (1 ) that steers the simulator, and then transfers the analogue calculations to the software,

• gas, brake, handbrake, horn,

· lift arm 1 , lift arm 2, lift arm 3, and lift arm 4 controlling the movements of the forks found at the front part of the forklift,

• a forward/reverse motion control arm allowing back-and-forth movement of the simulator,

• a left/right signal control,

· a front/top/rear headlight control,

• a wiper control,

• a beacon lamp control (2) allowing control of the beacon lamp (7),

• an emergency button that allows giving emergency warning,

and also, positioned on the operator seat, it comprises:

· a seat switch (3) adjusting the seat, and

• a seatbelt switch (4) adjusting the seatbelt. All of said steering wheel (1 ) arm control parts operate digitally.

The lift arm 1 comprises 2 digital buttons for movement of the forks found at the front part of the forklift. Said lift arm 1 is used for providing back-and-forth movement of said forks. The lift arm 2 provides up-and-down movement of said forks via up-and-down angular movements. The lift arm 3 provides left-and-right side movements of said forks via up-and-down angular movements. The lift arm 4 operates as a card reader for operating the system according to the invention. Said lift arm 4 allows back-and-forth movement of a carrier apparatus, which is called attachment and used for carrying the load, except the fork that is attached on the forklift.

Said arm 1 , arm 2, arm 3, and arm 4 operate in an analogue manner. Said steering wheel (1 ) arm control parts comprise status control LEDs (C) at their sides and the activity status of said parts is understood according to the on/off situations of said status control LEDs (C). Status control LEDs (C) are left signal, right signal, forward direction, backward direction, lower headlight, upper headlight, rear headlight, wiper, and beacon lamp (7) LEDs. The on/off situation of said status control LEDs (C) are also controlled by electronic control card 1 (6).

The forklift training simulator according to the invention is simulated based on the below given situations:

- load-capacity graphic situation,

- battery charge capacity situation,

- standing up from the seat while the forklift is in motion,

- movement while the seatbelt is worn/not worn,

- while going uphill,

- a sudden turn while going above a certain speed,

- a sudden turn when the fork is too high, - a forward movement when the fork is too high,

- a forward movement with high amount of load,

- in case of hitting a person,

- in case of hitting another vehicle,

- in case of dropping/damaging load,

- in case of hitting any object.

2 electronic cards are found in the forklift training simulator system. One of said cards is the electronic control card 1 (6) that performs control, or in other words, transfers analogue information to the simulator computer (22). Digital and analogue entries of the control systems (B) are processed by means of electronic control card 1 (6) developed with Arduino. If the control systems (B) are active, the status control LEDs (C) are illuminated by using the exit legs of electronic control card 1 (6) and thus indicate that the digital entry information are transferred. The other card is electronic control card 2 (27), which transmits digital data from the simulator computer (22) to the beacon lamp control (2) and vibration motor (28). The beacon lamp (7) becomes active via relay when one of the controls found on the steering wheel (1 ) is active (or in other words, control by electronic card 1 (6)) or by means of the software (when the forklift goes backwards, containing information for lighting of the beacon lamp (7)). When said beacon lamp (7) lights, the backward warning sound operates in the sound system. The vibration motor (28) is driven with the information taken from the simulator computer (22), using the exit leg found on electronic control card 2 (27). Said simulator computer (22) transmits the impact force to said electronic control card 2 (27) and the vibration motor (28) operates during that time period. The communication between electronic control card 1 (6), electronic control card 2 (27), and the simulator computer (22) is made through a USB cable as a serial communication. Cable connections are made with electronic control card 1 (6) and electronic control card 2 (27) from all of the control systems (B) found within the simulator according to the invention. The simulator computer (22) has MS Windows system. Said simulator computer (22) needs to have a strong graphics processor and 4 full HD HDMI outlets, and the processor level needs to be high enough to operate simulator software. At the same time, said simulator computer (22) is required to be connected to a network and be able to communicate with other devices via a wireless network device (9). It is aimed to ensure that the software runs smoothly by means of speakers (A), SSD, and high RAM characteristics. The speaker (A) sound support consists of a central speaker (16), a rear left speaker (17), a rear right speaker (18), a front left speaker (19), a front right speaker (20), and a subwoofer (21 ). These speakers are required for providing a real-like experience by providing sounds from the directions of impacts.

A tablet (10) can be mounted onto said indicator panel (1 1 ) both for use as a forklift indicator panel (1 1 ) and to check the simulator settings. Said tablet (10) transmits images and commands by communicating with the simulator software found on the simulator computer (22) by means of the wireless network device (9). The software found on said tablet (10) is prepared and compiled on Unity3D platform for Android, separate from the simulator software.

A card reader (8) to be mounted to the front panel of the forklift is connected to the simulator computer (22) by means of a USB cable and when any card is read on said card reader (8), the card information of said card is transmitted to the software. In this way, the information about the presence of a competent operator for using said forklift is received and the information of said operator is recorded. When said card is removed from said card reader (8), the operation of the forklift is prevented and the driving characteristics can be recorded in the driving chart of the card holder. An instructor can make adjustments on the simulator for instructing a forklift operator/student, by connecting to the wireless network device (9) by means of the instructor computer (5). The simulator software is prepared using Unity3D platform. All the controls, virtual environment physics, and connections are made through said software. Said software includes visual support for 4 different angles. The operation is made in 3 dimensions and the environment can be monitored and analyzed from 4 different visual angles.

By means of correct positioning of the speakers (A), impact and other sound directions are ensured to be perceived correctly by the forklift operator. In this way, the virtual environment is made more realistic.

The simulator cabin is fixed on a trailer and thus made mobile. While the training simulator is fixed on one part, about 2 m of the other fixed part is spared for placing the battery and rectifier that provide energy production for said simulator cabin. Another part is designed as the training room in around a 5 m area, and designed for on-site education for occupational safety and technical trainings. The required tools and spare parts for said technical education are found in a cabinet fixed inside. Moreover, the education room is completely designed according to the needs in field conditions by providing a blackboard.

Below, the operating principle of the solar panels providing energy production is disclosed:

- Solar panels generate 3.12 kWp power.

- The system can continuously be fed by generating 1 .5 kW to 2.5 kW energy depending on the daylight, season, and position.

- The battery group is continuously charged with the charger when there is daylight.

- When connected to the mains, the system operates in parallel with solar energy.

- When there is no mains or genset, the battery group can feed the system 6 to 10 hours depending on the load situation. The battery and charger situation is sent to the software system via a

GPRS modem through CanBus using a battery tracking system.

The battery charge situation and efficiency are reported on said software system.

Solar pane! operation technique

Solar Panels SoSar Inverter

260 Wo x 12 Galvo/Agilo 3k W

Solar DC

Distribution box

Mains Inlet

Single phase MainsfGenset Victron Grid inverter AC Charges 220V 50 Hz Automatic Transfer MultiPlus 24V 5000 Distribution Box

Spare Diesel Spare Battery Charger Generator 5 kW 24V 250 Ah Seiectiva 2050

CanBus Battery Tracking System > GPRS modem

Receiving data through

the software system

Scheme 1 : Solar panel operating technique In the invention, a power distribution panel (29) is found, which allows distribution of the energy required by the forklift training simulator system to relevant components. Said energy can be generated by means of solar panels.

All kinds of storage areas encountered in forklift sector (closed storage shelf system, open area shelf system, inside container, box truck, flatbed truck, piled up products, paper bobbins etc.) are included in virtual environment.

Occupational accident scenarios are generated in virtual environment by placing people and forklifts that move and follow a certain route, and thus occupational accident components and accident situations are analyzed. Steering wheel (1 ) control of operators are aimed to be improved by placing tracks formed of cones in the simulator. By means of a computer camera (23) found in the simulator system according to the invention, while the operator uses the simulation, he/she is watched by an instructor on an external screen (26) and all the simulation is recorded to be watched later on. Photos of people who attend the simulation are printed out by means of a photograph printer (25) and given them as a souvenir.

In addition, the operator has 100 points while starting the training. As the operator makes mistakes, said points are reduced and in the end, he/she is decided to pass or fail depending on the final score.

Claims

A forklift training simulator system allowing an operator to enter into a simulator cabin and move within a simulation scenario, and it is characterized in that; it comprises:

• control systems (B) found on said simulator and controlled by the operator according to the simulation scenario,

• electronic control card 1 (6), which is connected to said control systems (B) and thus transfers the information received from the control systems (B) to the simulator computer (22), and turns the status control LEDs (C) on or off according to the activity situation of the control systems (B),

• a simulation software installed simulator computer (22), which allows transfer of simulation visuals to screens (D), communicates with the instructor computer (5) and tablet (10) by means of a wireless network device (9), and controlling the simulator in accordance with the control systems (B) information received from electronic control card 1 (6),

• a wireless network device (9) providing wireless network communication between a tablet (10), a simulator computer (22), and an instructor computer (5) found on the same network,

• an instructor computer (5) transmitting the images and commands by communicating with the simulator software found on the simulator computer (22) and allowing remote control of the forklift training simulator system,

• a tablet (10) allowing control of the forklift training simulator system, transmitting the images and commands by communicating with the simulator software found on the simulator computer (22) by means of the wireless network device (9), and mounted on the indicator panel (1 1 ) found within the simulator cabin,

2. A system according to Claim 1 , characterized in that; said screens (D) are the left screen (12), right screen (13), and front screen (14) positioned outside the simulator cabin, and the rear screen (15) positioned at the rear part of the simulator cabin.

3. A system according to Claim 1 , characterized in that; it comprises speakers (A) enabling making sounds in accordance with the simulation scenario by means of the commands received from the simulation computer (22).

4. A system according to Claim 3, characterized in that; said speakers (A) are central speaker (16), rear left speaker (17), rear right speaker (18), front left speaker (19), front right speaker (20), and subwoofer (21 ).

5. A system according to Claim 1 , characterized in that; it comprises status control LEDs (C) positioned within said simulator cabin and displaying the active/passive situations of the control systems (B).

6. A system according to Claims 1 or 5, and it is characterized in that; said status control LEDs (C) comprise LEDs that display the active/passive situations of the left/right signal control, forward/backward movement control arm, front/top/rear headlight control arm, wiper control arm, and beacon lamp (7).

7. A system according to Claim 1 , characterized in that; it comprises a card reader (8), which connects to the simulator computer (22), reads the card containing the information of the forklift operator using the simulator, and records this information.

8. A system according to Claims 1 or 7, and it is characterized in that; said card reader (8) is mifare card reader.

9. A system according to Claim 1 , characterized in that; it comprises: • a vibration motor (28) driven by said electronic control card 2 (27) and enables the operator to feel the shock experienced in case of an accident, in accordance with the impact information coming to electronic control card 2 (27) from the simulator computer (22), and

• electronic control card 2 (27) controlling the beacon lamp (7) and the vibration motor (28) in accordance with the digital data it receives from the simulator computer (22).

10. A system according to Claim 1 , characterized in that; it comprises a computer camera (23) allowing monitoring of the operator from an external screen (26) while he/she uses the simulator, recording the operator behaviours during the simulation, and allow the operator to watch himself/herself later on.

1 1 . A system according to Claims 1 or 9, and it is characterized in that; it comprises a USB cable enabling serial communication between electronic control card 1 (6), electronic control card 2 (27), and the simulator computer (22).

12. A system according to Claim 1 , characterized in that; said simulator cabin is a forklift cabin.

13. A system according to Claim 1 , characterized in that; said control systems (B) comprise:

• a gas pedal enabling acceleration of said simulator,

• a brake pedal decelerating said simulator,

• a handbrake,

• a warning horn, and

· a warning emergency button.

14. A system according to Claim 1 , characterized in that; in order to control the forks found at front part of simulator, said control systems (B) comprise:

• lift arm 1 ,

• lift arm 2,

• lift arm 3, and

• lift arm 4.

15. A system according to Claim 1 , characterized in that; said control systems (B) comprise:

• a left/right signal control,

• a front/top/rear headlight control,

• a wiper control.

16. A system according to Claim 1 , characterized in that; said control systems (B) comprise a seat switch (3) adjusting the seat.

17. A system according to Claim 1 , characterized in that; said control systems (B) comprise a beacon lamp control (2) allowing control of the beacon lamp (7).

18. A system according to Claim 1 , characterized in that; said control systems (B) comprise a steering wheel counter (30), which calculates the rotational movements of the steering wheel (1 ) and then transfers the analogue calculations to the software.

19. A system according to Claim 1 , characterized in that; said control systems (B) comprise a seatbelt switch (4) adjusting the seatbelt.

20. A system according to Claim 1 , characterized in that; said simulator comprises a photograph printer (25) allowing printing out the photos taken by means of the computer camera (23).

21 . A system according to Claim 1 , characterized in that; said system comprises a wireless keyboard/mouse (24).

22. A system according to Claim 1 , characterized in that; said simulator comprises an external screen (26).

23. A system according to Claim 1 , characterized in that; said system comprises a power distribution panel (29) allowing distribution of required energy to relevant components.

24. A system according to Claims 1 or 23, and it is characterized in that; said system comprises solar panels that meet the required energy demand.