Note: Descriptions are shown in the official language in which they were submitted.
WO 2022/026144
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ON-BOARD CHARGING STATION FORA REMOTE CONTROL DEVICE
BACKGROUND ART
[000i] Materials handling- v,:ehicles are commonly used for
picking stock in-
Ntitel-touses and distribution centers. Such vehicles typically- include a
power writ and
a load handling assembly, which may include load carrying -forks. The vehicle
also
has control structures for controlling operation and movement of the vehicle,
[00021 ht a typical stock picking -operation, an operator
fills orders from available
-stock items that are located in storage areas provided along one or more
aisles of a
-warehouse or distribution center. The operator drives the vehicle between
various
pick locations where item(s) = are to be picked. The operator may drive the
vehicle
either by using the control structures on the vehicle, or via a wifeless
remote control
device that is associated with the vehicle., such. as the remote control
device disclosed
.commonly owned U.S. Patent No, 9,082,293, the entire .diselosure of which is
hereby incorporated by reference herein.
DISCLOSURE OF INVENTION
[0003l in accordance with a fast aspect, -0 system is
provided comprising:. a
materials handling vehicle; a wearable remote control device comprising: -a
wireless
communication system including a wireless transmitter and a rechargeable power
source; a receiver at the vehicle for receiving transmissions from the
wireless
transmitter; a controller at the vehicle that is communicably Coupled to the
receiver,
the controller being responsive to receipt of the transmissions from* remote
control
device; and a charging station. at the vehicle. The charging station may
charge the
rechargeable power source of the wearable remote control device. The charging
station may comprise a visual indicator configured to indicate one or .inere
charging state of the rechargeable power source when coupled to the charging
station,
a charging state of the rechargeable: power source when removed from the chug*
station, a pairing status between the wearable remote control device and. the
.vehicle
controller, or that the remote control devie is physically connected to the
charging
station,
100041 The visual indicator may display a. first color when
the remote control
device .is attached to the charging station: The yisual indicator may display
a second
color when the remote control device has been paired to the vehicle
controller.
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[0(1051 The visual indicator may provide one of a flash
display Or a fully filled
display.
[0006] The visual indicator may provide a visual indication
as. a cue for an
operator to pod:mil an: action. The action may be a test: to confirm that the
remote
control device is functional and can communicate with the vehicle,
[00071 The visual indicator may define a first visual
indicator, and the charging
station may further comprise a second visual indicator. The first visual
indicator and
the second visual indicator may be configured to be. activated independently
of each
other such that either the first visual indicator is activated while the
second visual
indicator is not activated or the second visual indicator is activated while
the first
visual indicator is not
[00081 The first visual indicator when activated may provide
one of an
intermittent display or a steady-state display_
[0009f The intermittent display may be operational at a first
pulsing rate or a
second pulsing rale, wherein the first aod second rates vary in frequency.
[00101 The second visual indicator when activated may provide
one of an
intermittent display, a partially filled display or a steady-state display.
WTI) The first visual indicator and the second indicator
may be configured to be
concurrently- activated.
[00121 The first visual indicator may be located proximate to
a docking port of the
charging station configured to receive the wearable remote control device and
may be
shaped to correspond to a graphic provided on the wearable remote control
device to
aid a user in positioning and connecting the wearable remote control device to
the
docking port of the charging station.
(001.3[ The first visual indicator may define a visual display
related to inserting
the wearable remote control device into the chargingstation.
1001(.41 The first or :second visual indicators either
individually Or in combination
with one another may provide a visual display related to the charging.
station, being
enabled or disabled
100151 The first or second visual indicators either
individually or in combination
with one another may provide a visual display related to a. charging error
occurring
with the charging station or the rechargeable power solute.
10016) The first or second visual indicators either
individually or in combination
with one another may provide a visual display related to a pairing error
occurring
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'between the .weerable remote control device and the vehicle.
10011 The first or second visual indicators either
individually Grin combination
with one another may provide a visual display related to a communication =
error
octurring: between the wearable remote control device and the conwollerõ
[00181 When the vehicle is turned on, the first indicator may
pulse -mil the
remote control device is connected -to a docking port of the charging station
such that
the first indicator is turned OFF When the remote control device is connected
to the
docking port,
[00191 When the vehicle is turned on, the first indicator
pulses until the remote
.control device is connected to a dockinkõ, port of the: charging station,
changes to a
steady state ON display after. the -remote control device is connected to the
docking
port and remains ON providing the steady state ON display until the
rechargeable
power source is fully charged.
ik9020i hi: accordance with a second aspect, a method is
provided for coupling .a
wearable remote control device to a charging station, wherein the wearable
remote
control device may comprise a wireless transmitter, a rechargeable power
source. and
at least one control causing the wireless .transmitter to wirelessly transmit
a request to
a controller of a materials handling vehicle; and wherein the materials
handling
.vehicle may comprise a receiver for receiving transmissions from .the
wireless
transmitter_ The controller may be communicably coupled to the receiver and
may be
responsive to receipt of the transmissions from the remote control device. The
diming station may be configured for charging the rechargeable power source of
the
wearable remote control device: and may comprise a visual indicator. The
method.
May eomprise,:. displaying, by the visual indicator, an indication of one or
more of: a
charging state of the rechargeable power source when counted to the charging
station,
a Charging state of the rechargeable power source when removed from the
.chatsing
station, a pairing. Status between the wearable remote control device and the
vehicle.
cootroller, or that The remote control device is. pllysicalIN connected to the
eitarging
station.
3
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BRIEF DESCRIPTION .OF THE DRAWINGS
10021 Figs 1 and 2 are side and top views of a. materials
handling vehicle
capable of remote: wireless operation according to various aspects of the
present
inventiow,
100221 fig. 2A is a side view of another materials handling
veincie capable of
remote wireless Operation according tO=varioas aspects of the present
invention:
100231 Fig. 3 is a schematic diagram of several components:.
of a material's
handling vehicle capable of remote Wireless operation: according to various
aspects of
the present invention:
100241 Figs 4-7 are views of a remote, control device
according to various aspects
of the oteserit invention;
100251 Figs. 8A and 8B are cut away views showing a remote
control device
beiug engaged with a charging station according to various aspects of the
present
invention;
100261 Figs, 9 and 10 are views of another remote control
device according th.
various aspects of the present
100211 Fig, 1.1: is a schematic diagram of several components
of a charging station
according, to various aspects of the present invention;
100281 Figs. 12-14 are views showing a remote control device
and a charging
station according to various aspects of the present invention;
100291 Fig. 15-is a schematic diagram of several coMponents
of a remote control
device according to various aspects of the present invention;
100301 Fig. 16 depicts a method according to various aspects
of the present
invention;
100311 fig, 17 depicts a pairing method according to various
aspects of the
present invention;
100321 Fig: 18 depicts another pairing method according to
various aspects of the
present invention;
100331 Fig, 19 depicts a method to re-pair a vehicle and a
remote-control device
according to various aspects of the present invention;
100341 Fig, 20 depicts a method to reestablish communication
between a vehicle
and a remote-control device according to various aspects of the present
invention:
100351 Fig. 21 depiets a method to charge a remote control
device according to
various aspects of the present invention;
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1,011361 Pig, 22 depicts another method to charge a remote
control device
according to various aspactsof the present invention;
[00371 Fig. 23 is a. schematic diagram of several components
of a kit according to
various aspects of the present invention;
[0381 Fig.. 24 is a view of another remote control device
according to various
aspects of the present invention;
100391 Fig 25 is: a schematic diagram illustrating various
aspects of the present
invention;
109401 Figs 26 and 27 illustrate a remote control device and
4.charging station
.constructed in accordance with a further embodiment
1004 ti Figs_ 28A.2.81 illustrate various slates the first and
second visual indicators
of the charging station ofFig& 2.6 and 27; and
[0042i Figs. 29A ¨ 29C illustrate various states for first
and second 'Visual
indicators of the charging station. of Figs. 25 and 27.
FIEST MODE FOR CARRYING OUT THE INVENTION
f004.31 In the following detailed description. of Mc
illustrated embodiments,
reference is made to the accompanying drawings that form a part hereof, and in
which
is shown by way of illustrationõ and not by way of limitation, specific
embodiments in
which the invention may be practiced. It is to be understood that other
embodiments
may be utilized and that changes may be made without &parting from the spirit
and
scope of various embodiments of the present invention.
Low Level Order Piczkinv Tr/./(..A
(00441 Referring now to the drawings, and particularly to
Figs. I and 2..õ
materiak handling 'vehicle .10, which is illustrated as a low level order
picking truck,
includes a load: handling assembly 12 that extends from a power unit 14, The
Vehicle
IQ forms part of a system 4 according to aspects of the invention, which
system wifl
be more fully described below. The load handling ass.etubly 12 includes pair
of
forks 16, each fork 16 having a load supporting wheel assembly .1.8. The load
handling assembly 12 may include other load handling features in addition to,
or in
lieu of the illustrated arrangement of the forks 16,. such as a load backrest,
scissors-,
type elevating forks, outriggers or separate height adjustable forks-, as a
few examples-.
Still further, the load handling assembly 12 may include load handling
features such
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aS
Oast, 11, load platform, collection.cagO.Or= other-support structure carried
by the
forks 16 or otherwise provided for handling a load supported and tarried by
the
vehicle 10: While the present disclosure is made with reference to the
illustrated
vehicle 10, it will be apparent to those of skill in the art that the vehicle
10 may
comprise a variety Of other industrial vehicles, such as a forklift truck, a
reach .track.õ
etc,. .and. that the following description of the invention with reference to
the Figures
should not be limited to an order picking truck unless otherwise specified.
Additionally, the vehicle 10 may be implemented in other formats, styles and
features,
including a vehicle 10 that does not include a load handling assembly, such as
a
tugger vehicle, etc,
(OW]
The iihiArated power unit 14 comprises a step-through operator's station
2.0 dividing a first end section of the power unit 14 (opposite the. forks
.16) from a
second end section. (proximate the forks 1.6). The operator's station 20
includes.t
platform 21 upon which an operator may stand to drive the vehicle 10 =dim¨ to
provide a position from Which the: operator may operate various included
features.of
the vehicle 10.
190461
Presence sensors 22 (see Fig..) may be provided to detect: the presence of
an operator on the Vehicle 10, For example, presence sensors 2.2 may be
located an,
above or under the platform 21 ,or otherwise provided about the operator's
Station 20:
in the exemplary vehicle 10 of Fig, .2, the presence sensors 22 are shown in
dashed,
lines indicating that they are positioned underneath the platform 21. Under
this
arrangement, the presence sensors 22 may comprise load sensors, switches, etc,
As
.an alternative,. the presence. sensors 22 may be implemented above the
platform 21,
such as by using ultrasonic, capacitive or other suitable sensing technology.
The
utilization of presence sensors 22 will be described in greater detail herein,
100471
According to one embodiment shown in Fig, 2, the vehicle 10 may include
.pole that extends vertically from the power unit 14 and includes an antenna
30 that
is provided for receiving control signals from a corresponding wireless remote
control
device 32. The pole may include a light 3 at the top, as shown in Figs.". and
1
According to another embodiment as shown in Fig.. 2A, the antenna may be
located
v!fithin other vehicle components, such that: the control signals from the
remote control
device 32. are received elsewhere on the vehicle 10, as will be discussed
below. TO
romotv control device 32 comprises an Odd-Won:al component: of the stem. S
t0;b0
described in more detail below.
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100481 The remote control device 32 is, Manually operable by
on went:tor,. e,g,.õ by
pressing a button or other control, to cause the remote control device 32 to
wirelessly
transmit at least a first type signal designating a travel request to a
vehicle I:0 that is
paired to the remote control device 32. The travel request is.a. command that
requests
the vehicle 10 to travel, as will be described in greater detail herein.
Although the
remote control device 32. is illustrated in Figs. I and :2 as a finger-mounted
structure,
numerous implementations of the remote control device 32 may be implemented,
including for example, a Owe structure, a lanyard or sash mounted structure,
etc.
Still further, the vehicle .1.0 and. the remote control device 32 may comprise
any
additional and/or alternative. features or nuplementations, examples of which
are
disclosed in U.S. Provisional Patent Application Serial No. 60/825,68l, filed
September 14, 2006õ entitled "SYSTEMS AND METHODS OF REMOTELY
CONTROLLING A MATERIALS HANDLING VEHICLE;" U.S. Patent Application
Serial No. 11/855,310, filed September 14, 2007, entitled "SYSTEMS AND
METHODS OF REMOTELY CONTROLLING A. MATERIALS HANDLING.
VEHICLE" now U,S. Patent N. 9,082,293, U.S. Patent Applieotion Serial NO..
11I8.$5,3.24, filed September 14, 2007, entitled -Symms AND METHODS OF
REMOTELY CONTROLLING A MATERIALS HANDLING VEHICLE" noW.1.1.$
Patent NO. 8,072;309; U.S. Provisional Patent Application Serial No.
61/222,632,
..filed July 2, 2009, entitled ".APPARATUS FOR REMOTELY CONTROLLING A
MATERIALS HANDLING VEHICLE;" U.S. Patent Application Serial :No.
12/631,007, tiled December 4, 2009, entitled "MULTIPLE ZONE SENSING FOR
MATERIALS HANDLING VEHICLES" now U.S. Patent No, 9,64.5,968; U.S.
Provisional Patent Application Serial No. 61 119,952, filed December 4, 2008,
entitled ''MULTIPLE ZONE SENSING FOR REMOTELY CONTROLLED
MATERIALS HANDLING VEHICLES;." and/or U.S. Patent NO, 7,07,689, issued
March 28, 2006, entitled 4TLECTRICAL STEERING. ASSIST FOR .MATERIAL
'HANDLING VEHICLE"; the entire disclosures of which are each hereby
incorporated by reference herein. Additional details in connection with. the
remote
control. device 32 will be discussed in detail below.
(00491 The vehicle 10 also comprises one or more comactiess
obstacle senSors40;
which are provided about the vehicle 10, ex.., towards the first end. section
of the
power 'unit 14 as shown in Figs. 1 and Z. The obstacle sensors 40 are operable
to
define at least one detection zone. For example, at least one detection zone
may
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define an area at least partially- in front of a forward Inlyekrig 4iNetion.
of the vehicle
when the vehicle 10 is traveling in response to a wirelessly received travel
request
from the remote control. device 32, as will also be described in greater
detail herein.
10501
The obstacle sensors 40 may comprise any suitable proximity detection
technologyõ such as ultrasonic sensors, image capture devices, infrared
sensnrOaser
.scanner Sensors, e, which are capable of detecting the presence of
Objects/bbstacles
or are capable of generating signals that can be analyzed to detect the
presence of
objects/obstacles within the predefined detection zone(s).
In the exemplary
embodiment illustrated in Figs, I and 2. the vehicle 10 includes a first
obstacle
detector 42 and a pair of second Obstacle detectors 44A and 448 mounted to the
power unit 1.4. The lust Obstacle detector 42 is spaced apart from the second
obstacle
detectors 44A and 44B along a vertical axis VA of the vehicle 1.0 defining a.
vertical
direction, i.e., the second obstacle detectors 44A and 448 are located below
(closer to.
the ground than) the first .obstacle detector 4:2, see Fig, 1, The second
obstacle
detectors 44.A. and 448 are spaced apart from each other along a horizontal
axis fi.A of
the vehicle 10 defining a horizontal direction, see Fig, 2,
100511
The first obstacle detector 42 may cotnprise a sweeping laser sensor
capable of detecting objects, 11.-ir example, in first, second, and third
zones Zr, Li, Z3
(also referred to herein as scan zones or detection zones)õ which first,
second, and
third zones .11, Z, &may comprise planar zones, see Figs. I. and 2. The second
zone
Z2 may comprise a 'stop zone", and the fitst and third zones Z1 and Z may
comprise.
left and right "steer bumper zones", such as the stop zone and the left and
right steer
bumper zones described in US. Patent No. 8,452,464, issued May 28., 2013,
entitled
"STEER CORRECTION EOR A. REMOTELY. OPERATED MATERIALS
HANDLING VEHICLE", the entire disclosure ofwhich is incorpOrated by reference
herein. ft is noted that the first obstacle detector 42 may be capable of
detecting
objects in additional or fewer zones than the three zories.4 Z.,
illustrated. in one
exemplan,, detection zone configuration, artyor all of the detection Miles may
be used
as disclosed in. &LS. Patent No. 9,002,581 issued April 7, 2015 and entitled
"OBJECT
TRACKING AND STEER MANEUVERS FOR MATERIALS HANDLING.
VEHICLES", the entire disclosure of which is incorporated by reference herein.
100521
The second obstacle detectors. 44A and 448 may comprise point laser
sensors that are capable of detecting objects between one or more of the zones
Zi, Z2,
Z1
f the first obstacle detector 42 and the vehicle 1.0, i.eõ underneath one or
more of
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the zones it, Z. Zs,as illustrated in Fig, I. and/ past the -zones Zr. Z,
ZLatidare
preferably- capable: of at least detecting objects -underneath the second
zone. Z. The
second Obstacle detectors 44A and 44B are: thus capable of detecting objects
located
in a non-detect zone DZ of the first obstacle detector 42, see Fig.. .1õ.
i.e., which #1011-
detoct zone 1)7 is defined as an area below the zones Z, Z. Zs and thus not
sensed by
the first obstacle detedtor 4.2. Hence, the -first obstacle detector 42
functions to detect
objects. located along a path of travel of the power unit 14 beyond the non-
detect. zone
DZ, while the second obstacle detectors 44A and 44B function to sense Objects
along
the path of travel of the power unit 14 in the non-detect zone DZ, which is
located just
in. front of the vehicle 10, as shown in Fig; 1.
(0053) Additional sensor configurations aud/ot detection
Zones may be used; such
as discussed in the various patents and patent applications incorporated, by
reference
herein.
[0054i The vehicle 10 shown in Figs. I and 2 further includes
a charging station
50 that comprises an additional component of the system 8 and. that is
provided tbr
charging a rechargeable power source of the remote control device 32.
Additional
details in connection with the charging station 50 will be described below,
Control System ,-16r Remote Operation n/cm Low Level Order Picking Mx*
[00551 Referring to Fig. 3., a block diagram illustrates a
control. arrangement for
integrating remote control commands with the vehicle .10. A receiver 102,
which may
be a Bluetooth Low Energy (BLE) radio, tbr example, is provided for receiving
commands issued by the remote control device 32. The receiver 102 passes the
'received control signals to a controller 103, which implements the
appropriate
response to the received commands and may thus also be referred to herein as
a.
.maiger controller. In this Mgard, the controller 103 is implemented. in
hardware and
may also execute software (Winding firmware, resident software. Micro-code,
etc.),
Furthermore, aspects of the present invention may take the form of .a computer
program product embodied in one or more computer readable mediunt(S). having.
computer readable program code embodied thereon. For example, the vehicle It)
may
include memory that stores the computer program product, which, when
implemented
by a processor of the controller 103, implements steer correction as described
more
fully herein.
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100561 Thus, the. controller 103 may define, of least in
part, a data processing
system saitable for storing and/or executing program code and may include at
least
one processor coupled directly or indirectly to memory elements, e.g., through
a
system hits or other svirahle connection. The memory elements can include
local
memory employed during actual execution of the program code, memory that is
integrated into a microcontroller or application specific integrated circuit
(ASIC)
programmable gate array or other reconfigurable processing device, etc.
100571 The response implemented by the controller 103 in
response to wirelessly
received commands, e.g., via a wireless transmitter 178 of the remote control
device
:32 (to be discussed below) and sent to the receiver 102 on the vehicle 10,
may
comprise one or more actions, or inaction, depending upon the logic that is
being
implemented. Positive actions may comprise controlling, adjusting or otherwise
affecting one or more components of the vehicle 10, The controller 103 may
also
receive. information from other inputs 104, e.g., from sources. such as the
.presence
sensors 22, the obstacle sensors 40, switches, load sensors, encoders and
other
devices/features available to the vehicle 10 to determine appropriate action
in
response to the received commands from the remote control device 32. The
sensors
22, 40, etc. may be coupled to the controller 103 via the inputs 104 or via a
suitable
truck network, such as a control area network (CAN) bus 110.
[00581 Man exemplary arrangement, the remote control device
32 is operative to
wirelessly transmit a control signal that represents a first type signal such
as a travel
command to the receiver 102 on the vehicle 10, The travel command is also
referred.
to herein as. a -travel signal", "travel request!' or "go signal". The travel
request is
used to initiate a request to the vehicle 10 to travel, e.g, -for as long.as
the travel Signal
is received by the receiver 102 and/or sent by the remote control device 32:,.
by a
predetermined amount, e,g., tocause the vehicle )0 to advance or jog in a
first
direction by a limited travel distance, or for a limited time, The first
direetion May be
defined, for example, by movement of the vehicle 10 in a power unit 14
first,i,e:,
forks 16 to the hack,. direction. However., other directions of travel may
alternatively
be defined. Moreover, the vehicle 10 may be controlled to travel in a
generally
straight direction or along a previously determined beadine, Correspondingly.
:the
limited travel distance may be specified by an approximate travel distance,
travel time
or other measure.
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10(159j
thil$, a first type signal received by tile roceiver 102 i communicatedlo
the controller 1.03:. IC the controller 103 determines that the travel signal
is a. valid
travel signal and that the current vehicle conditions are appropriate
(explained in
greater detail in US. Patent No., 9,082,293, which isalready incorporated by
rek,rence
herein), the controller 103 sendsa igurcti to the appropriate control
configuration of
the vehicle 10 to advance and then. stop the vehicle 10. Stopping the vehicle
10 may
be implemented, for example, by either allowing the vehicle to to const to a.
step or
by initiating a brake operation to cause the vehicle. 10 to brake to a stop.
109601
As an example, the controller 103 may be communicably coupled to a
traction control system, illustrated as a traction motor controller 106 of the
vehicle 10.:
The tnction motor .0 ontroller 106 is coupled to a traction motor 107 that
drives at
least one Steered wheel 108 of the vehicle 10. The controller 103 may
communicate
with the traction motor controller 106 so as to acceletate, decelerate, adjust
and/or
otherwise limit the speed .of the vehicle 10 in response to receiving a travel
request
from the remote control device 32. The controller 103 may also be coma/Unica*
.coupled to a steer controller 112. which is coupled to a steer motor 114 that
steens..at.
least one. steered µvheel 108 of -the vehicle it). In this regard, the vehicle
10 may be
controlled by the controller 103 to travel an intended path or maintain an
intended
heading in response to receiving a travel request from the remote control
device 32.
[00611
As yet another illustrative example, the controller 103 may be
communicably coupled to a brake controller 116 that controls vehicle brakes
117 to
decelerate, stop or otherwise control the speed of the vehicle 10 in response
to
receiving a travel request from the remote control device 32. Still further,
the
controller 103 may be communicably coupled to other vehicle features, such as.
main
contactors 118, and/or other outputs 119 associated with the -vehicle 10,
*here
applicable, to implement desired- actions in. response to implementing remote
travel,
functionality.
10062 I
According to various aspects of the present invention, the controller 103
may communicate with the receiver 10.2 and with the traction. motor controller
106 to
operate the vehicle 10 under remote control M response to receiving travel
commands
from the associated remote control device 32. Moreover, the controller 103 may
be
configured to perthrm various actions if the 'vehicle 10 is traveling under
remote
control in response to. a travel request and ah obstacle is detected in one or
more of the
detection zone(s)
In this regard, when a travel signal is received by the
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controller 103 from the remote control. dice 32, arty nunribo of factors
rtn,ay be.
considered by the controller 103. to determine whether the received travel
signal
should be acted upon to initiate andfor Sustain movement of the vehicle 10.
[00631 Correspondingly, if die vehicle 10 is moving in
response to a eammand
received by the remote control device 32., the controller .103 may dynamically
Ater;
control, adjust or otherwise affect the remote control operation, e.,q., by
stopping the
vehicle 10, changing the steer angle of the vehicle 10, or taking other
actions.. Thus,
the particular vehicle featuresµ the awe/condition of one or more vehicle
features,
vehicle environment., etc., may influence the manner .in which the controller
103
responds to travel requests from the remote control device 32.
[00641 The controller 103 may refuse to acknowledge a
received travel request
depending upon predetermined candition(s), tg.õ that relate to environmental
or
operational factor(s). For example, the controller 103 may disregard an
otherwise
valid travel request. based upon information obtained from one or more of the
sensors
22, 40. As an illustration, according to various aspects of the present
invention,. the
controller 103 may optionally consider factors such as whether an operator is
on the
vehicle 10 when determining whether to respond to a. travel command from the
remote control device 32.. As noted above, the vehicle 10 may comprise at
least. one
presence seosor 22 for detectio.g whether an operator is positioned. on the
vehicle :10.
In this regard,õ the controller 103 may be further configured to respond to a
travel
request to operate the vehicle 10 under remote control When the presence
sensor(s) 22
designate that: uri operator is on the vehicle 10. Thus, in this
implementation, the
vehicle 10 caanot he operated in response to wireless commands from the remote
control device. 32 unless the. operator is physically off of the vehicle 10,
Similarly, if
the obstacle sensors 40 detect that an object, including the operator, is
adjacent andf.or
proximate to the vehicle 10, the controller 103 may refuse to. acknowledge 4
travel
request. from the., remote control device 32. Thus, in an exemplary
implementation, an
operator must be located within a limited range of the vehicle 10., e.g.,
close enough to
the vehicle 10 to be in wireless communication range (which. may. be limited.
to. set a.
maximum distance of the operator from the vehicle 10), Other arrangements may
alternatively be implemented,
(00651 Any other number of reasonable conditions, factors,.
pammeters or other
considerations may .also/alterainively be implemented by the controller 103 to
interpret and take action in response to received signals from the transmitter
178.,
1)
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Other exemplary factors are set out i gteater detail in. U,S.. Provisional
Patent
Application Serial No. 60/825,688, entitled "SYSTEMS AND METHODS OF
REMOTELY CONTROLLING A MATERIALS HANDLING VEHICLE;" U.S.
Patent Application Serial No, 1 I/855,310. entitled "SYSTEMS AND METHODS OF
REMOTELY CONTROLLING A MATERIALS HANDLING VEHICLE' now U.S,
Patent No. 9,082,293; US, Patent Application Serial No, TI./855,324, entitled
"SYSTEMS AND METHODS OF REMOTELY CONTROLLING A MATERIALS
HANDLING VEHICLE" now' U.S. Patent No.. 8,072.309; U.S, Provisional Patent
Application Serial No, 61/222,632; entitled "APPARATUS FOR. REMOTELY
CONTROLLING. A MATERIALS HANDLING VEHICLE;' U.S.. Paint Application
Serial Na.. 12/631,007, entitled "MULTIPLE ZONE SENSING FOR
MATERIALS
HANDLING VEHICLES" now U.S, Patent No. 9,645,96K; and U.S. Provisional
Patent Application Serial No. 61/119,95.2, entitled '"MULTIPLE. ZONE SENSING
FOR REMOTELY .CONTROLLED MATERIALS HANDLING VEHICLES;" the
disclosures of which are each already incorporated by reference herein,.
f00661 Upon acknowledgement of a travel request, the
controller 103 interacts
with the traction motor controller 106, e.g,, directly or indirectly, e.g.,.
via a..htei such
as the CAN bus 110 if utilized, To advance the vehicle 10. Depending upon the
particular implernentationõ the controller 103 may interact with the traction
motor
controller 106 and. optionally, the steer controller 1.12,-to advance the
vehicle 10 for as
lone as a travel control signal is received. Alternatively; the controller 103
may
interact with the traction motor controller 106 and optionally, the sleet
controller 112,
to advance the vehicle 10 for a period of time or for a predetermined distance
in
response to the detection and maintained actuation of a -travel control OD the
MIX*
control device 32. Still further; the controller 103 may be configured to
"time Our
and stop the, travel of the vehicle 10 based.upmi a predetermined event, such
as
exceeding a predetermined time period Or travel distance regardless of the
detection of
maintained actuation of a corresponding control on the remote control device
32.
f0067j The remote control. device 32 may alSO be operative to
transmit a wend
type signal, such. as a "step signal", designating that the vehicle 10 should.
brake
and/or otherwise come to rest The second type signal may also be implied,
e.g,õ after
implementing a "travel' command, e.g., after the vehicle to has traveled a
predetermined distance, traveled for a predetermined time, etc,õ under remote
control
in response to the travel command. If the controller 103 .determines that a
WiteleS*
13
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teCeiVOCI signal. isa stop signal, the eontrollet 103 sends a signal to the
traction motor
controller 106, the brake controller 116 and/or other truck component to bring
the
vehicle 10 to a rest. .As an alternative to a stop signal, the second type
signal may
comprise a. "coast signal" or a "controlled deceleration signal' designating
that the
vehicle 10 should coast, eventually slowing to rest.
[00681 The time that it takes to bring the vehicle 10 to a
complete rest May vary
depending for example; upon the intended application; the environmental
conditions,
the capabilities of the particular vehicle 10, the load on the vehicle 10 and
other
similar factors. For example. after completing an appropriate jog movement,
it: may
bedesirable to allow the vehicle 10 to "coast sonic distance before coming to
rest so
that the vehicle 10 stops -slowly. This trio' be achieved by utilizing
regenerative
braking to slow the vehicle 10 to a Stop. Alternatively, a braking operation
may be
applied, after a predetermined .delay time to allow a predetermined range of
additional
travel to the vehicle 10 after the initiation of the. stop operation.. It may
also. be
desirable to bring the vehicle 10 to a relatively quicker stop, e.g., if an
object iS
detected in the travel path of the vehicle 10 or if an immediate stop is
desired after*.
successful jog operation. For example, the controller 103 may apply
predetermined
torque to the braking operation. Under such conditions, the controller 1:03
niay
instruct the brake controller 116 to apply the brakes 117 to stop the vehicle
10.
100691 Also shown in Fig, is the on-vehicle chorally
station 50 that can
communicate with the controller 103, As will he explained in more detail
below, the
charging station. 50 can be used to charge a rechargeable power source 180 of
the
wireless remote control. device 32, The charging station 30 may be located on
a side
portion of the vehicle to, for example, proximate to the operator's statioa.
;0. near
manual driving controls of the vehicle 10 as shown in Fins, 1 and-2, or on a
side panel
of the power unit 14.
[00701 A pairing system 34 can utilize a close range system
to. wirelessly
communicate with a compatible close range system on the wireless remote
control
device 32, Using the pairing system 34, 4 vehicle 10 and wireless remote
control
device .32. can be "paired" such that a vehicle 10 will transmit and receive
messages
from only its paired wireless remote, control device 32, In addition to, or as
an
alternative to close range or other types of wireless. communications, such
a.s near-
field communication. (NFC.), the pairing system 34 can also Use physical
contacts that
allow electrical communication between the remote control device 32 and the
vehicle
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10, at least= for the, initial pairing procedure, For exothple,. electrical
contacts Qf the
charging station 50 used for charging: the remote control device :32 could be
used for
pairing the vehicle It) to the remote Control device 3Z as willbe described M
greaser
detail herein. The pairing system 34 includes components that physically
implement
the communication method te..g, Blue.tooth, NFC,
Wi-Fl, etc.) used to send
messages and includes. components that programmatically exchange information
in an
agreed upon protocol to establish and maintain a. pairing,. Thus, the pairing
system 34
includes a device that can execute programmable instructions to implement a
predetermined algorithm and protocol to accomplish pairing operations.
f0071I
In Fig, 3, the charging station 50, the receiver 1.02, and the pairing system
34 are depicted as distinct functional blocks. However, one of ordinary skill
will
recognize that two or .mote of these components can be Combined iii a
singleelement
to provide A multi-function device.
kVsteni
f0(1721
As noted above, the vehicle 10 (including the charging station 5(1) and the
remote control. device 32. form the system: $ in accordance with an aspect. of
the
present invention. The remote control device 32 and the charging station 50
will now
be described in uttn.
[0073j
With reference to Fiat,. 4-8, the remote control device 32 according to. This
embodiment is a fineer-mounted device, although the. remote control device 32
could
take other forms, such as a glove-mounted device, a wrist-mounted device, A
lanyard-
mounted device, etc. The remote control device 32 may be mountable over one
finger, two fingers, or more than two fingers of the operator.
100741
The remote control device 32 illustrated in Figs, 4-8 compriseS a
polymeric rigid base 112 (see Fig, 6) and a polymeric rigid upper housing 74.
The
base 172 and upper housing 174 are coupled together via any suitable manner
and
define an internal area 176 for receiving internal components of the remote
control
device 32, including a wireless communication system 456 including a wireless
transmitter 1778 ,..such. as the wireless transmitter 178 described above with
reference to
Fig. 3, and a rechargeable power source 180. In one exemplary embodiment, the
wireless transmitter 178 comprises a model BCA1.12 I manufactured hy SiLabs,
his
noted that the term,' -transmitter" and "receiver es used herein are intended
to mean
a device capable of one-way communication, ix., the device only transmits., or
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receives signals, or a device capable of two-way communication, such as a
transceiver, Which both transmits and receives signals,
f00751 The rechargeable power source 180 may be a. super
capacitor, a high
capacity batter?, etc. For example, an AVX supercapanitor, model SCCR20E335PRB
can be used, which has a rated voltage of 3V and a capacitance of 3.3F, The
rechargeable power source 180 is small enough to fit within the internal area
17(i
while also having enough capacity on a substantially full charge to yield a
use period
of the remote control device 32 of at least two hours, at least lbw' hours, at
least eight
hours, or more, A Use period of up to eight hours may be preferable to
correspond
with an eight,hotir working shift for an operator.
(0076) A supercapacitor (also called a super-cap or
ultracapacitor) is a high
-
capacity capacitor with capacitance values much higher than other capacitors
but,
typically with lower voltage limits that bridge the gap between electrolytic
capacitors
and rechargeable batteries. They typically store 10 to 100 times more energy
per unit
volume Or Mass than electrolytic capacitors, can aceept and deliver charge
mach
faster than batteries:, and tolerate -many more charge and discharge cycles
than
rechargeable batteries, Because supereapacitors can be used in applications
requiring
many rapid chargeldischarge cycles, some embodiments of the remote control
device
32 can include a supercapacitor as the rechargeable power source 180, in
embodiments of the present invention, the current supplied to the
superc.apacitor can
be limited to about 2A and can accomplish charging to a full Charge in about.
2
seconds or less. R.egardless of the specific type of rechargeable power source
180
used, embodiments of the present invention contemplate recharging the
rechargeable
power source 180 to a desired amount, such as to a full charge state, or to a
charge
state less than a substantially full charge state (as will be discussed in
detail herein)
via the charging station 50 within a desired charging period. The power
supplied ki
the rechargeable power source 180 by the charging. station 50 may be varied in
accordance with the capacity of the rechargeable power source 180, the desired
churRe amount, andiar the desired charging period, as will be discussed in
greater
detail herein.
100771 With reference to Fig. (5, the remote control device
32 further comprises a
securing. stnicture 188 for securing the remote control device 32 to one or
more
fingers of the operator's. hand. The securing structure 188 in the embodiment
shown
in Fig, ti comprises a holding strap 190 that includes, for example, hook and
loop tape
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'fasteners 191 to secure the holding strap 190 to a single finger, e,a, the
index. finger,
of the operator. The remote control device 32 is provided with first and
second slots
.192-A and 1928 located on opposed ends or the remote control device 32 for
receiving
the holding strap 190,
f00781 The holding strap 190 shown in Fig. 6 defines a first
finger receiving area
194 for receiving the single finger Ov (See Figs. 1 and 2) of an operator
using the
remote control device 32. Both right and left hand versions of the remote
control
device 32 may be created. The remote control device 32 is releasably held on
the
operator's index linger via the holding strap i 90. In one exempt:1n,
embodiment, a
first end 190A of the holding strap 190 is threaded through the first slot
192A and a
seoond end 1908 of the holding strap 190 is threaded through the second slot
192B.
The JIM end 190A of the holding strap 190 may be permanently fastened to the
rigid
base 172, e.g_, via stitching or gluing, while the second end 19013 or the
holding strap
190 may be releasably inserted through the second slot 1:928 and doubled back
such.
that the hook and loop tape fasteners 191 are engaged with one another to
fasten the
holding strap 190 to the operator's linger. The holding strap 190 can he
adjusted to
accommodate fingers of different sizes or such that the remote control device
32
could be worn over a glove (not shown). It is noted that other types of
holding straps
190 may be used.
[00791 The remote control device 32 limber comprises at least
one control,
depicted in Figs. 4.8 as first, second, and third controls 196A.C. The
controls 196.A-
C each comprise .a button 1.97A-C and a two-state switch 198A.0 located
underneath
the corresponding button 1.97A-C, The switches 198.k.C. are communicably
coupled
to the wireless communication system 456, such that actuation of each one of
the
controls 196A.0 causes the Wireless transmitter 178 to wirelessly transmit a
respective request to the vehicle 10. In the exemplary re-mote control device
32
depicted in Figs. 4-8i the first control 196A comprises a travel button 197A
that,. when
pressed, causes: the wireless transmitter 178 to wirelessly transmit a request
fOr the
vehicle i0 to tel across a floor surface; the second control 1968 comprises a
horn
button 19713 that, when pressed, causes the wireless transmitter .1 78 to
wirelessly
transmit a request for the vehicle 10 to sound a hornfaudible alarm and the
third
control I 96C comprises a brake button I 97C. that, when pressed, causes the
wireless
transmitter 178 to wirelessly transmit a request for the vehicle to stop (if
inoVing
under wireless control) and, optionally, to power down.
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10(18gi The remote control device 3.2 is compact, and
substantially the entirety of
the remote control device. 32 is mountable and positioned directly over the
index.
finger of the operator. Hence, interference of the operator performing working
tasks
caused by -wearing the remote control device 32. is minimal or non-existent.
The
remote control device 3:2 is durable and long lasting since the rigid base 172
and the
upper housinn 1.74 are preferably formed from a durable and rigid. polymeric
material,
such as acrylonitrile hatadiene styrene (ABS),.polyearhonate or nylon. The
rigid bast
72 and the upper housing 174 define a durable, generally non-flexible and
rigid
structure,
WSJ] An operator can. easily actuate The travel button.
.197A. manually via his/her
thumb to cause the wireless transmitter 178 to witelessly transmit at least a
tint type
signal designating a travel request or command to the vehicle 10. It is
contemplated
that the travel request may result in the -vehicle 10 traveling for as long as
the operator
holds down the :travel button 197A, or by a predetermined distance or for a
predetermined amount of time. The horn button 197B and the brake button 197c
can
he actuated by the operators opposite hand, for example,
f0(182) As shown in Figs.. 4 and 5, the remote control device
32 further comprises
one or more charging contacts 210, it being noted that additional or fewer
charging
contacts 210 than the four shown. may be used, e.g., one charging contact 210
or two
or more charging contacts 210 may be used. Additionally, the remote control.
device
32 farther includes one or more sensors in the form of first presence contacts
212,
illustrated in' Figs, 4 and 5.as a single last presence contact 212 located
intermediate.
the four charging contacts 210. The charging and first presencc. contacts 210,
212
may be arranged within openings 214 formed in an outer surface of the upper
housing
174 of the .remote control device 32. The tops of the charging and first
presence
contacts 210, 21.2 may he. positioned below the enter surface of the upper
housing,
the charging and first presence contacts 210, 212 may be recessed within the
openings 214, which may prevent damage to the digging and first. presence
comets
210, 212 due to accidental contact. it is noted that other configurations for
= the
number, orientationõ and placement of the charging contacts 2,10 and the first
presence
contact(s) 212 could be used without departing from the scope and spirit of
the
invention.
[00831 in embodiments, the charging: contacts 210 mate or
engage with element%
e.g., electrical contacts or charging elements 220 of the oh-vehicle charging
station 50
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(1:0 be discussed "below), and the fast presence contact 2 /2 mates or
engages. with. A.
complementary second sensor in the form of a second presence contact 222, such
asa
Switch, pogo pin or pressure pin, for example, of the on-vehicle charging
station 50;
shown in Figs. Sik and 8f3 and will be described in more detail herein. Ir is
noted
that one or more of the charging contacts 2.10 and corresponding
chargingnlements
220 nay be provided for redundancy. oue example, the low charging
contacts 210
illustrated in Figs. 4-7 and four charging elements 220 illustrated. in Figs.
.1.2-14 could
be set up as two pairs of redundant contacts/elements 210/220, where charging
of the
rechargeable power source lW as discussed below) is enabled as long AS one
charging contact 210 from each pair is. engaged with and. in electrical
commtinication
with its corresponding charging element 220.
100841 Embodiments of the present invention also contemplate
contactleSs,
induction, charging in which the rechargeable power source 180 of the
re:11101C COlitt-01
device 32. can be charged by the remote control device 32 being in close
proximity to,
or on the surface of.; a compatible induction charging station (nor shown),
Sticli an
induction el-laming station may be located, for example, in a driving or
steering
control of the vehicle 10 such that the rechargeable power KM= 180 may
be'Ci1Oged
while the operator is manually driving the vehicle 10 from the operator's
station 20,
100851 Figs. 9 and 10 illustrate another exemplary remote
control device. 32,
where like reference numbers correspond to similar components to those listed
above
for Figs. 4-8. The remote control device 32 according to this embodiment is
intended
as a two,linger design, Le, the securing structure. 188- in the embodiment
shown in.
Figs. 9 and 10 comprises a holding strap 190 that defines first and second
finger
receiving areas 194, 195 for receiving the. index and middle fingers of an
operator
using the remote control device 32, The remote control device 32 according. to
Figs. 9
.and 10 includes two charging contatts '210 instead of four charging contacts
210 in=
the remote control device 32. of Figs.. 44 The remaining components,. of the
remote
control device 32 of Figs. .9 and 10 may be ,generally the same as the remote:
control
device $2 of Figs. 4-8 and thus will not be described in detail herein.
100861 Fig, .1.1. provides a functional block-level diagram
of a vehicle charging
station 50 in accordance with the principles of the present invention in which
the
pairina system 34 is incorporated into the charging station 50. As explained
in more
detail below; the charging station 50 can include the receiver 10, eg.. a
Bluetooth
Low Energy (BLE) radio 402 that can communicaW with the vehicle's controller
103.
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Although not .shown, the commtatication can be throug,h the. vehicles CAN bus
and,
thus, the charging station 50 can include a CAN bus interface. The charging
station
50 can also include one or more light emitting diodes (LEDs) 404 Or other
visual
indicators that help convey information to an operator. For xample, one LED
may
be used to indicate that a remote control device 32. is presently coupled:
with the
charging station:. 50. Other LEDs may indicate a current state of charge of
the remote
control device's rechargeable power source Ha A current limiter 406 or other
protection circuitry can be provided that helps ensure a remote control device
32 is
.safely re-Charged as the current limiter 406 allows the voltage from the
vehicle's
power source to be provided to the charging elements 220 a the charging
.station 50
for charging the remote control devices rechargeable power source 1110. These
charging elements 22.0 interface with the charging contacts 210 of the
rernotecontrol
device 32 and provide the electrical connection between the vehicle's power
source
and the rechargeable power source 180 of the remote control device 32. The
second
presence contact 222 engages with the first presence or.114t,t .212. to
.detect When a.
remote control device 32 is physically connected to the charging station 50
500 that
the charging contacts 210 are engaged .with the charging dements 2.20.
According to
embodiments, upon the second presence contact 2.22 being, engaged by the first
presence contact 212, the pairing process is initiated,
[00871 It is noted that the first and second presence
contacts. 212., 222 can
respectively be. provided on either the remote control device 32 or the
chargitu.,,.station
50. That is, while the second presence contact 222 is illustrated an the
charging.
station 50 and the first presence cOn1a4 212 on the remote control device 32,
the
second presence. contact 222 could be located on the remote control device 32
and the
first presence contact 212 could be located on the Charging station 50.
100881 The relationship between the second presence contact:
2.22 and the
charging elements .220 is such that the charging .contuts 210 of the remote
control
device 32 and the charging elements 220 of the charging station. 50 are in
contact with
one another bethte the second presence contact 222 engages the first presence
contact
.21..2 when a charging procedure is being initiated, see Pig. 8.A., which
shows that the
height of the second presence contact. 222 is less than the height of the
charging
elements 220, the heights measured with respect to top surfaces of element
housings
.220A and a .second presence contact housing 222A from which the :respective.
charging elements 220 and second presence contact 222 extend. 'The supply of
power
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from the &urging station. 50 to the ten:10W coutrel device 32 via the ainrging
elements/Charging contacts 220/2.10:is only initiated after the second
presence contact
222 .engages the first presence contact 212: During a charging procedure, the
charging contacts 210 of the remote control device 32 are engagedee!itli the
charging
elentents 220 of the charging station 50, and the second presence contact. 222
is
engaged with the first presence contact 212, thus enabling the supply a pourer
from
the deal-gine St1111011 50 to the remote control device 32 via. the charging
elements/Charging contacts 220/210, see Fig. 8:1a, After the rechargeable
power
source l'80 is charged to the desired amount* egõ flatly charged or charged to
a
desired amount less than faily charged as described herein, the supply of
power from
the charging station 50 to the remote control deviee. .32 via the charging.
elements/chanting contacts 2201210 is eta off. In the: CaSe that the remote
control
device 32. is removed from the charging station 50 before the rechargeable
power
source kW is charged to the desired amount, as the remote control device. 32
is
removed from the charging Station 50, the second presence contact 222
disengages
from the first presence contact 212 prior to the charging elements 220
disengaging
from the charging contacts 210. The supply apower from the charging station 50
to
the rechargeable power source 180 of the remote control device 32. via the
charging
elements/charging contacts 220/210 is cut off when the second presence contact
222
disengages from the first presence contact 212. This arrangement is intended,
to
prevent arcing between the charging elements 220 and the charging contacts
210.,
Using the first presence contact 212 and second presence contact 222 in the
form of .a
pogo pm provides the following advantages: a. precise control of the relative
heights
of the second presence contact 222 and the charging elements' 220; a. small
footprint.,
good seal, e.g,ete prevent moisture from entering the second presence contact
housing
222A from around the second presence contact 222; and it allows for the
differentiation between the first presence contact 212 and a foreign object,
such as it
piece of metal, which prevents electrical current from flowing into such a
foreign.
object if were to be placed in contact with the second presence contact 222
and one
or more of the charging elements 220.
00.891 As an alternative to the presence contacts 212, 222
being used. to initiate
the supply of power from the charging station 50 to the remote control device:
32õ.4
separate switch may. be present that the operator engages to begin a charging
operation. In one. specific embodiment using induction charging, such a switat
can be
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1.1101pOrateii into the vehicle's steering control, such that the operator's
gripping of
the steering control is detected and tharging is subsequently enabled.
f00901 Controls 414 for providing controlling signals to
operate the LEDs 404 can
he from various sources. While the remote control device 12 is operated within
range
of the charging station SO, the controller 103 can receive information about
the state
of charge of the rechargeable power source 180 and drive the display of the
LEDs 404
t convey this information utilizing a. CAN bus interface:, for example. When
the
remote control device 32 is coupled with the charging station: 50 the LEDs 404
can be.
used to convey a) that a remote control device 32 is physically connected to
charging
station 50, 1'0 that there: is a remote control device 32 pmsently paired with
the
controller .103 of the vehicle, C) the progressichateing state of a current
charging
operation, and/or d) the charging state. of the rechargeable power source 180.
The
information for items c) and d) may be sent to the charging station 50 by the
remote
control device 32, for example, over a Bluetooth Low Energy (BLE) connection,
which BLE connection Will be discussed in greater detail below. According to
one
aspect, since the pairing and charging processes are performed very quickly,
the
progre.s&charging state of a. current ebarging operation may nOi be displayed
by the
LEDs 404, The remote Control device 32 may store its charging profile and then
send
the charging profile to the charging station 50,. e.g., over the BLE
connection,. after the
remote control device 3.2 is removed from the charging station SO, *herein the
charging profile may be evaluated, for example, by the controller 103, to
determine if
a proper charge of the .rechargeable power source 180 occurred. The second
presence
contact 222 can also send. control signals to controls 414 that indicate
Whether
charging 'contacts 210 of the remote control device- 32 are properly .coupled
with
corresponding charging elements 220 of the charging station 50.
10091.1 Figs. .12,14 illustrate other features of die charging
station $0 located at the
vehicle 10. The charging station 50 can include one or more physical
protrusions or
guide structures 420 that help glade the remote control device 3:2. into
correct
alignment 50 that the station's charging elements 220 are aligned with: the
charging.
contacts 210 of the remote control device 32, i,eõ the euide structure(s) 420
align, the
remote control device 32 in the proper orientation for charging the
rechargeable
power source 180,Ta Fie. 12, a single guide. structure 420 including a
plurality of
guide surfaces is shown. The guide stnieture(s) 420 can be placed around the
location
.of the charging elements. 220 and can be shaped or slanted so thnt the
remote. control
22
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device 32 is physically guided to correct alignment as tlig operator places
the ientote
control device 32 in the charging station 50..
[0092] In Fig: 13, the LEDs 404 incinde a visual indicator
424 that indicates :a.
remote control device 32 is attached to the charging station 50. The visual
indicator
424 may illuminate, flash,. or progressively fill as a first color to indicate
that the
remote .control device 3.2 is attached to the chargine station 50, and as a
seCond color
or fully filled first color to indicate that the remote control device 32 has
been paired
to the vehicle controller I oa, i.e., the visual indicator .424 may use the
second coloror
fully filled first color to serve as a pairing indicator that confirms the
establishment of
communication between the remote control. device 32. and the vehicle 10.
Additionally, according to one optional aspect of the invention, the LEDs 404
may
flash, illuminate as a second color, or provide Some other visual indication
after
establishment of communication between the remote control device 32 and the
vehicle 10 as a cue for the operator toperform an action as a test to .confinn
that the
remote control device 32. is functional and an communicate to the, vehicle
10.;.stich as
by pressing the horn button .197B and brake button 197C concurrently. It IS
understood that separate indicators may be used. for the purposes of
indicating that
remote control device 32 is. attached to the chargi ire station 50 and to
indicate that the
remote control device 32 has been paired to the vehicle 10, as opposed to a
.single
indicator that can serve both functions.
[0093l The LEDs 404 can further Serve as an indicator to
identify the progress of
a recharging operation when the remote control device 32 is attached. When the
remote control device 32. is not. attached to the charging station 50, the
LEDs 404 may
'serve as an indicator to indicate, the present state of charge of the
rechargeable power
source 180 of the remote control device 32. Thus, the LEDs 404 can indicate
the state
oreborge of the rechargeable power source 180 both. when charging the
rechargeable
power Same; 180 at the charging station $0 and during use of the remote
control
device 32, i.e., while the operator is using the remote control device 32 to
assist in
pert-brining work operations. In one exemplary embodiment, the LEDs 404 can
comprise ft series a lights, each light representing a level of the .state, of
eharge.of the
rechargeable power source 180.
10094) in Figs. 12 and 14, an exemplary location of the
second presence contact
.222 is shown within the charging station 50. It is noted that the remote
control device
32 illustrated in Figs. 12-14 is the single-finger embodiment of Figs. 4-7. It
is also
23
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noted that the ebarging contacts. 21.0 and first presenee contact 212 of the
aingle-finger
and the two-linger embodiments could be arranged. to mirror one another. Thaa,
the
same eharging station 50 could be used for :instances of the single-finger or
tWoarmger
remote control devices..32,
00951
The charging station 50 may be located at various locations on the vehicle
10, its location should be such that it does not interfere. with normal
operation of the
vehicle 10, but where it is accessible and convenient tbr the operator.. .1n.
embodiments the charging station 50 is located at the operator's: station 29
(ace Figs-
I and 2., where the charging station 50 is located, in the operator's station
20 but is also
accessible from outside of the vehicle 1.0); on a. surface of one of the sides
cif the
vehicle 10; or, for the induction charging embodiment, wiflim the steering
control of
the vehicle 10,
(00961
The charging station 50 may include a voltage regulator (not shown) that
transforms the power trona the vehicle 10 received by the charging station
50.into a
regulated direct current Dc) voltage signal. selected based on the Charging
characteristics of the rechargeable power source I80. For example, in an
embodiment
in which the rechargeable power .source 180 is an AVX auppreapacitor described
above or equivalent device, a. 3V DC. (1%) supply voltage could be provided to
the
current 46,
100971
U is noted that the remote control device 3' is described herein as haVine
anexemplary configuration and may be structurally modified without departing
from
the spirit and scope of the invention. For example, one or more components or
the
remote control device 32 may he combined in an integral component, or
components
May be suhatitutedafor alternate components that effect a aimilarlidentical
purpose_
100981
In one embodiment, charging of the rechargeable power .source ISO via.the
charging station 50 occurs when one or more charging contacts 210 engagp.
corresponding charging element 220 of the .charging Station 50,
In some
embodiments, at least two charging contacts 2:10 or at least tout charging
contacas.210
and .corresponding charging elements 220 are present, in some embodiments, one
or
more pairs of charging contacts .210 are provided, wherein at: least one
charging
contact 210 from each pair must engage a corresponding charging element 220
for
charging to occur. As described above, at least one of the remote control
device 32
and the charging station 50 On include a second -presence contact 222, such As
a
switch, for example. The second presence contact 222 detects whether or not
bent
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104$1 one charging contact 210 is correctly engaged with. the ut least one
:corresponding charging element 220 for charging: the rechargeable power
smite.
wherein if a correct engagement is detected, the transfer of power to the
rechartteable
power source 1.80 is enabled by the charging station 50,. and if a correct
engagement is
not detectedõ the transfer of power to the rechargeable power source 1.80. is
not
enabled by the charging StatiOn 50,
[00991 Furthermore, the arrangement of the remote control
device 32 and the
charging station 50 is configured such that the second presence contact 222
indicates
the removal of the remote control device 32 from the charging station. 50,
which
ceases the transfer of power to the rechargeable power source 180 from the
charging
station .50, before the at least one charging contact 210 is disengaged from
the at least
one corresponding charging element 220. Hence, the transfer of power from the
charging station 50 to the rechargeable power source 180 is ceased before the
at least
One Charging contact 210 is disengaged from the at least one corresponding
charging
element 220. This may be effct<led, for example, by setting the heights :of
the
charging elements 220 and the second presence contact 222 as shown in 'Fig,
'8.A,
wherein the charging elements 220 are pushed down. into respective element
housings
220.4 before the second presence contact 222 cringes efirst presence contact.
212,
as the remote control device 32 is inserted into the charging station 50,
[001.001 Fig, 15 is a block-level functional diagram of the portions 450 of
the
remote control device 32 that relate to recharging the rechargeable power
source 180.
The other portions of the remote: control device 32 such as, tor example,
those that.
relate to the mechanical actuators are not depicted in Fig., 15. As noted
above, the
remote .control device 32 can include one or more Charging .contacts 210 that
are
configured to engage a corresponding charging element In some embodiments, the
charging: elements may be the charging elements 220 of the charging station
50. In
other embodiments, the charging elements may be those of an adapter that
connects to
a source of power to recharge the rechargeable power source 180.
100101j The remote control device 32 can include 'protection circuitry 452
that
limits electrical parameters such 43 voltage and/or current to he within
expected
operating ranges. Charge controller and disconnect circuitry 454 can monitor
the
voltage being received from the protection circuitry 452 as well as monitor
the present
:foie of charge of the rechargeable power source 1$0 in order to determine.
When to
stop charging the rechargeable power source 180. for example, according .to.
one
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exemplary embodiment, When the charge on the recliargeable power source 180
reaches 3V, the charge controller and disconnect circuitry. 454 can operate to
stop
further charging. The charge controller and disconnect circuitry 454 can
include
temperature sensing capabilities or be connected to 4 temperature sensor so
that the
rechargeable power source 180 cum be charged (or discharged) to different
charging
levels. In some embodiments, the rechargeable power source 180 is discharged
to a
high temperature state of charge, e.gõ a Iess than fully charged state, if a
sensed
temperature is determined to be above a predetermined set:point temperature.
In one
exemplary aspects of the invention, the sensed temperature is an ambient:
temperature.
In an alternative aspect, the sensed temperature is a battely temperature, to
sonic
embodiments, the rechargeable power source 180 is charged at the charging
station 50:
LO a predetermined charge level less than a 100% chap: level if a sensed
temperature
is determined to be above a predetermined threshold temperature. This may help
prevent damage to or degradation of the rechargeable power source 180.
f001021 As shown in Fig. 15, the remote control device 32 can include the
wireless
communication system 456 such as, fOt example, a BEE radio that can
communicate
with the BEE radio 402 of the charging station 50 via a BEE connection,. The
wireless communication system 450 alittor the BEE radio 402 of the charging
station
50 can be configured, for example, to enter a low power mode when the remote
control device 32 is being paired to the vehicle 10 and/or the rechargeable
power
source 180 of the remote control device 32 is being charged at the charging
station 50,
e.g., to ensure that only a remote control device 32 that is. within a minimum
distance,
for example, less than five inches or less than three inches corresponding to
the signal
strength of the communications- received from the remote control device '32,
from the
charging station 50 is recognized as the remote control device 32 to pair.
with.
Additionally, if the BEE radio 402 of the charging station 50 were to identify
two Or
more retnine control devices 32 available for pairing and could not determine
the
correct one for pairing, the charging station 50 may not pair with any of the
available
remote control devices 32 and may require the operator to repeat the pairing
prooess..
.pS0CialinziPairing a Remote Control Mvicelvilli a Vithide-
1001031 figs, 16-18 illustrate details of exemplary pairing processes in
accordance
with aspects of the invention The remote control device 3:2 and vehicle 10
descriNd
above will be used in describing the pairing processes of Figs. 16-18, but it
is
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1.111CW1-51004: that other configuratiouststyles of the remote control deviee
and vehicle
could be paired together in accordance with the invention.
[001041 With reference to Fig. 16, the method 500 begins when the vehicle
operator retrieves a remote control device 32 at 502. If the remote cOatrol
device 32
is a wearable device as in the embodiments (.4' figs. 4-8 and 9-10, the remote
control
device 32. is also donned by the operator, e,g, by securing the holding strap
190w the
operator's finger(s).
0.5I The vehicle operator then initiates a power on sequence to enable the
vehicle 10 for operation, i.e., the operator starts the vehicle 104 504, In
starting the
vehicle 10 the operator may be required to provide Ikvin information to the
vehicle
=10.. This information may be provided for, by example, entering a personal
identification number (PIN) into a control panel of the vehicle 10, by
utilizing a key
fob to provide the logon ID to the vehicle 10, or [he operator's PIN may be
encoded
into a memory device, such as a radio-frequency identification (RFID) chip
that is
integrated into the remote control device 32.
f001061 The operator then starts a pairing operation with the vehicle 10 at
506, and
the pairing system 34 then pairs the remote control device 32 used by the
operator to
the vehicle 10 at 508. Details of two exemplary pairing operations will be
described
in detail below with reference to Figs. 17 and 18.
1001071 Once paired, the system 8 may provide a visual indication as such eg.,
by
displaying a message tut the Vehicle 10, illuminating the LED 424 in a
predetermined
color, making an audible or visual queceõ etc., that indicates that the
pairing is
complete.
1001081 In accordance with an aspect, of the invention, the remote control
device 32
may be unpaired from the vehicle 10 by powering down the vehicle 10. Othor
exemplary methods for unpairiug the remote control device 32 from the
vehicle10 :are.
described below hi exemplary use case&
1001091 The operation or two example pairing systems 34 are described in
relation.
to Figs, 17 and .18, respectively, which are flowcharts of example methods
'5() and
600 for pairing a vehicle 10 and a Terillite control device 32 using a pairing
system 34
that is part of the charging station. 50 On board the vehicle 10, The
descriptions of the
methods 550 and 600 of Figs. 17 and 18 begin as the remote control device 32
is
inserted into the charging station 50, corresponding to stop 506 of .Fig, 16,
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1001101 With reference to Fig: 17 and the method 550. at 552, when the second.
presence contact 222 is engaged by the first presence contact 212 as the
remote
control device 32 is inserted into the charging station 50, the T31,E radio
402 of the
charging station 50 is enabled so as 10 start Scanning or listening for nearby
.BLF
transmissions, As discussed above, the engagement of the second presence
contact
222 by the first presence contact 212 can also cause the current limiter
40.410.be
enabled so that power from the vehicle 10 can be provided to the charging
contacts
210 from the charging elements 220, which will cause the rechargeable power
source
180 of the remote control device 32 to be recharged. Accordingly, pairing and
charging operations are initiated by the, single action. or coupling the
remote control
device 32 with the charging station 50. In lien of using BLE transmissions to
pair the
remote control device 32 to the vehicle controller 10.3, the remote control
device: 32.
can. be paired to the vehicle controller 103 by direct physical contact
between, for
Mani*, the charging contacts 2.10 and the charging elements 22(1
Alternatively,
dedicated pairing contacts knot shown) may be proVided on the remote control
device.
3.2 and the vehicle 10, eõg,õ at the charging station 50, -to pair the remote
control
device 32 to the vehicle controller 103 via direct physical contact. Such
pairing
contacts on the remote control device 3.2 and the vehicle 10 could. be engaged
with
each other .coneurrently with the engagement of the charging contacts 210 to
the
charging elements 220 such that the pairing process could occur at the same
time.as
the charging process. These pairing contacts mild be used solely for
performing
message exchanges for pairing operations..
1001111 According to one aspect of the invention, where the pairing process is
accomplished wirelessly, at 554, the remote control device. 32 detects that a
whaw is
present at its charging contacts 2.10 and begins transmitting BLE
advertisements via
the wittdess transmitter 1.78 indicating that the remote Control device 32 is
available
for communicating with nearby devices:
1001121 In response., the BLE radio 402 of the charging station 50 can receive
one
of the transmitted advertisements and, at 556, 'issue a ELE scan request
directed to the
specific remote control device 32 associated with the: received advertisement.
If the
FILE radio 402 of the charging station 50 were to identify two or more remote
control
devices 32 available for pairing, ie., by receiving .BLE advertisements from
two or
more remote control devices 32 while scanning or listening for nearby 13LE
transmissions, the vehicle 10 may not pair with any of the available remote
control
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devices 32 and *lay require the operator to repeat the pairat,g proem by
removing the
remote control device 32 from the charging station 50 and then reinserting the
remote
control device 3.2 into the Chanting station 50.
1001131 At 558, the remote control device 12 mponds to the. son request with.
unique identification code, which the BLE radio 402 receives.
1001141 At 560; the vehicle 10 verities the code and instructs the BLE radiO
402 to
open a BLE connection and begin communicating with the remote control device:
32
[00115i At 562, once a communication session is established between the -
remote
control device 32 and the charging .station 50,.. a predetermined pairing
algorithm can
be implemented between the remote control .device 32 and the charging station
54.) to
complete the pairing operation at 5.64. Once paired, the vehicle 1.0
wirelessly
communicates with the remote control device :32, and the controller 103 of
the. vehicle
is capable of implementing wireless requests received from the remote control
device 32.
100161 In the example flowchart described above with respect to fig. 1.7, a
similar
method can be performed to pair the remote control dice 3.2 to the vehicle
lOusing,
for example, one or more of the charging. elements 220 of the charging station
SO and
the charging contacts 210 of the remote control device .32, or the dedicated
pairing
contacts noted above. Instead of the messages being. transmitted and received:
via
wireless/BLE radios, the same or equivalent types of messages can be
communicated
:through the elements/contacts. 220/210 via various protocols, The messages
can be
modulated and transmitted over one of the elements/contacts 2.201210 providing
the
voltage. in either ease, pairing of the vehicle 10 and the remote control
device 32 can
occur concurrently With the charging of the rechargeable power source 1.80 of
the
remote control device 32v.
[0101.7) With reference to Fig. 18 and the method 600., at 6Ø2õ when the
second
presence contact 222 is engaged by the first presence centaet 21.2 as the
remote
control device 32 is inserted into the charging station 50, the BEE radio 402
of the
claming station 50 is enabled with a predetermineke.g. 1.500m. timeout *3 as
to
start scanning or listening -for nearby BLE transmissions from remote control
devices
32. As discussed above, the engagement of the second presence contact 222 by
the
first presence contact 212 can also cause the current limiter 406 to be
enabled so that
power from the vehicle 10 can be provided co the charging contacts 210 froni
the
charging elements 220, which will cause the rechargeable power source. 180 Of
the
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remote control device 32 to be recharged,. According,ly parting and charging
operations are initiated by the single action of coupling the remote control
device 32
with the charging station 50 such that a component of the remote control
device 32
physically contacts an element of the charging station 50. In lieu of using
.BU
transmissions to pair the remote control device 32 to the vehicle controller
10.3 the
remote control device 32 can he paired to the vehicle controller 103 by direct
physical
contad between, for example, the charging contacts 210 .and the charging
elements
220. Alternatively, dedicated pairing contacts (not shown) may be provided on
the
remote control device 32 and the vehicle 10, el.+, ttt the charging station
50, .to pair
the remote control. device 32 to the vehicle controller 103 via direct
physical contact.
Such pairing contacts ort the remote control device 32 and the vehicle 10
could he
engaged with each other concurrently with the engagement of the. charging
contacts
210 to the charging elements 220, such that the pairing process could occur at
the
same time as the charging process. These pairing Contacts could be used solely
for
pertbrming message exchanges fityr pairing operations,
1001181 At 604, the signal strength of the BLE transmissions between the
wireless
tratIsnlittar 178 .and the BL F: radio 402 may be d.eerease4 during the
pairing process to.
help 'prevent any other 'nearby vehicles '10 from 'receiving the BLE
transmissions from
the remote control device 32.
[001191 According to one aspect of the invention, where the pairing process iS
accomplished wirelessly, at 606, the remote control device 32 detects that a
voltage is
present at its charging contacts 210 and begins transmitting Bit
advertisements via
the wireless transmitter 1.78 at a predetermined. rate, e.g., a 20ms rate with
a
predetermined tnneout, .e,g4 7000rns timeont, indicating that the remote
cputrol
device 32: is available for communicating with nearby vehicles 10. If the
BLEradio
402 DI the charging station 50.were to identify two Or more remote control
devices 32
available for pairing,. ike., by receiving .131_,E, advenisevents from two. or
more remote
control devices 32 while scanning or listening for nearby 13LE transmissions,
the
vehicle 10 may not pair with any of the available remote control devices 32:
and may
require the operator to repeat the miring process by removing the remote
control
device 32 from the charging station 50 and then reinserting the remote control
device
:32 into the charging station 50,
l0111.20i The charging Station 50 may provide power to charge the rechargeable
power source 180 for up to about, eg., 1000ms before the BLE advertisements
are
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sent from the Wifelegs triausinitler 178. Charging of the rechargeable
poWet.soorce
180 by the charging station 50 will be discussed in detail below.:
100121.1 In response to receiving the BLE advertisements from the. Avireless
transmitter 178, the BLE radio 402 of the charging station 50 can, at 60$..
issue a ME
scan request,.
1001221 At 610, the remote control device 32 receives the scan request from
the
BLE radio 402 and uses the address of the .BLE radio 402 to create a unique
identification code, which the remote control device 32 sends back to the BEE
radio
402 at 612,
1001231 At 614, the vehicle 10 verifies The code and instructs the BLE radio
402 to
open a BLE connection and he communicating with the remote control device 32..
it is noted that if the vehicle 10 receives more than one valid identi
fication code
during step 614, for example, if the vehicle 10 receives identification codes
from two.
different remote control devices 32;. pairing. will tinl the vehicle 10 may
issue an error
message or other warning, and the: operator will be required to. repeat the
pairing
process by removing the remote control device 32 from the charging station 50
and
then reinserting the remote control device 32 into the charging station $0,
1001241 At 616, once a communication session is established between the remote
control device 32 and the charging station 50, the pairing operation may be
Completed, and the signal strength of the BLE transmissions between the
wireless
transmitter 1713 and the BL radio 402 may be increased back to their normal
levels at
61g.
1001251 The operator may be required to perform an action at. 620 as A. test
to
confirm that the remote control device 32 is functional and can communicate to
the
charaing. station 50, such as by pressing a button sequence on the remote
control
device 3.2, for example, by pressing the horn button )971-i and brake button
.I.97C
coucurrently:
1001261 Once paired., the vehicle 10 wirelessly communicates with, the remote
control device 32, and. the controller 103 of the vehicle 101s capable of
implementing.
wireless requests received from the remote control device 32.
1001271 in accordance with aspects of the invention, a pairing period (which
is a
time period that it takes to establish communication between the remote
control
device :32 and the vehicle 10 and commences with steps 5521602 and ends.with
steps
564/616) may be less than the charging period (Which is the time it takes to
charge the
31
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rechargeable power some 180 to a desired charge state at the chargin station
50),
wherein charging of the rechargeable power source 180 will be discussed below
in
connection with Figs, 21 and 22.,
[001281 Referring to Fig. 19, in accordance with an additional aspect of the
invention, after performing work operations, the vehicle operator niay need to
temporal* leave the vehicle 10, e.g,, to take a break. An. exemplary method
700 is
illustrated tar shutting down, restarting and re-pairing the vehicle 10 to the
remote
control device 32 used by the operator, The operator powers down the vehicle
10 at
70.2, so as to take a break, etc: After a time, the vehicle operator powers
the vehicle
back. up. During this time of the break, the remote control device 32 may
continue
to be paired with the vehicle 10 for up to a predefined time period. This
state of
maintained pairing between the vehicle .10 and the remote control device 32
may be
indicated, for example, on a touchscreen (not shown) provided on the vehicle
10, by
illuminating the LED 424 in a predetermined color, pattern, etc. Thus, if the
operator
powers the vehicle 10 back Up before the predefined time period expires at 704
the
vehicle 10 may detect the remote control device 3.2 at 706, wherein the remote
control
device 32 remains paired with the vehicle .10. in this regard. the operator
may or may
not have to take some type of action at 708, such as by pressing a button on
the
vehicle 10, e,g,on the charging station 50, on the tonchscreen, etc.. Or by
pressing a
button sequence on the remote control device 32.
[00129f A successful operator action at 708 results in a confirmation of the
pairing
between the remote control device 32 and the vehicle 10 at 710. A visual queue
may
be displayed on the indicator (the LED 424) to signify the pairing, e.g., by
illuminating the LED 424 in the second color noted above,
1001301 Alternatively, according to this aspect of the invention, if the
operator
powers the vehicle 10 back up after the predefined time period expires at 712,
dle
operator may be required to re-pair the remote control device 32 to the
'vehicle 10 as
with the initial pairing, e,g,, by inserting the remote want device 32 into
the
charging station 50 at 714.
1001311 With reference to Fig. 20, an example method 800 is illustrated for
reestablishing communication between the remote control device 32 and the
vehicle
10 after a period of no vehicle-related activity has been pertbrined. At 802,
the
controller 103 on the vehicle. 10 detects that no vehicle-related activity has
been
performed for a: given period of time after communication between the remote
control
32
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device 32 and the vehicle [0 :has been established_ L'Ixemplary vehicle-
,related.
activities Include driving the Vehicle 1'(I (either .manually using the
manual. controls in
the, operates station 20, other manual controls, e.g.,. on the side of the
vehicle- .10, or
via the remote control device. 32), standing on the plafom .21, moving or
placing an
nem on the load handling assernbly 12, etc. .At 804, if no vehicle-related
activity
takes place for greater than a first predetermined amount of time after
communication
between the remote control device 32 and the vehicle- 10 is established, the
communication between the remote control device 32. and the. vehicle 10 is
terminated
and must he re-established using the pairing system 34 at 806, tõeõ by
inserting the
remote control device 32 into the charging station 50 at the vehicle: 10. This
state of
terminated pairing between the :vehicle 10 and the remote, control device 32
May be
indicated, for example, on the touChscreen, by illuminating: the LED 424 in a
predetermined color, pattern, etc..
[001321 At 808, if no vehicle-related activity takes place for less than a
.second
.predetermined amount of time after communication between the remote. .control
device 32 and the vehicle 10 is established, the second predetermined amount
of time
equal to or less than the first predetermined amount of time, the
communication
between the remote control device 32 and the vehicle 10 is terminated but can
be re-
established without the pairing system 34, elõ, by performing a confirmation
method
utilizing the remote control device 32 at: 810. The confirmation method may
.comprise, for example, the operator carrying out a button sequence on the
remote
control device 32, such as by long-pressing one or mote of the buttons 197A=<,
This
state of pairing between the vehicle [0 and the remote control device 32: may
be
indicated, lbr example, on the touchscreen, by illuminating the LED 424. in A
predetermined color, pattern,. etcõ
[001.33 I Fig. 21 is a. flowchart: of an .e.xample method_ 900 for charging a
.remote
control device in accordance with the principles of the present invention, In
particular, the remote control device may be the same as or similar to the
remote
control device 32 discussed herein, and can include a wireless communication.
system.
456 including a wireless transmitter 178. (e.g. capable of one or .two-way
communication), a rechargeable power source I /1.(), and at least. one control
(e.g.,
controls I 96A-C1 that causes the wireless transmitter 178 to wirelessly
transmit a
request to a controller of a materials.handling whiffle 1Ø
33
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[001341 The -method 900 for chinging a retnote control device 32 begins at;
902 by
initiating contact between a component of the remote control device 32 and an
element of a charging station 50, the charging station 50 located at the
vehicle 10, and
then sensing contact between the remote control device component and the
charging
station element.. As described above, the remote control device 32 can include
one or
more charging contactS 210 that are each arranged to engage a corresponding
charging element 220 of the charging station 50, such that when they are
engaged, a
second presence contact 222 or a similar device engages a corresponding tirst
presence contact 212 to detect or sense that the charging contact(s) 210 and
charging
element(s) 220 are in contact with one another. However, other components of
the
remote control device 32 and other elements of the elle-ming station 50 may be
used to
detect/sense the initiation of contact.
100135j Next, at 904, a charging period. is started; wherein power is supplied
from
the charging station 50 to the rechargeable power source 180. As described
above, as
an example, circuitry of the. charging station it) is .configured such that
upon the
sensing of contact between the charging contact(s) 210 and charging element(s)
220,
power is supplied from the Charging station 50 to the charging contacts 2W of
the
remote control device 32 to charge the rechargeable power source: 180, Once
the
rechargeable power source 180 is substantially fully charged Or charged to the
desired amount less than a substantially full state of Charge), the remote
control device
32 can be removed from the charging station 50,
10tH 361 Thus, the method of Fig_ 2.1 continues, at 906. with interrupting
contact
between the remote control device component and the charging station element.,
and
sensing the interruption of the contact between the remote control device
component
and the charging station element. As described above, the charging contact(s)
210 of
the remote control device 32 and the charging elemengs) 220 of the charging.
station
50 are arranged such, that as the two systems are disengaged, that state can
be detected
or sensed. One example is the second presence contact :222 that can detect
when the
remote control device 32 is being removed from the charging 'station 50.
1001371 Finally, upon the sensing of this interruption at 906; the charging
station
50 can cease the supply of power from the charging station 50 to the
rechargeable
power source I 80 at 908, thus ending the charging period., it is noted that
the second
presence contact 222 can be located on the remote control device 32 and its
disengagement can result in ceasing the supply of power from the charging
station 50
34
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to thOteehargeable poWeE Witrte 180, The supply of power. -from. the charging
italion.
50: to the .n,..chargeable power source 180 may also be ceased. when the
rechargeable
power source 180 is charged up to the desired amount (either fully charged or
charged.
up to. a desired amount: less than fully charged)., as described herein,
1001381 The method 900 can include other optional steps shown in Fig, 21. For
example, the method 900 Can also include confirming the establishment of.
communication between the remote control device 32 and the vehicle 10 at. 910,
e.g,,
with .at least one of an audible or visual queue. The method 900 can .further
include,
while the remote control device component in contact with the charging station
element, establishing. communication between the remote control device 32 and
the
vehicle 10 (cg, pairing) during a pairing period at 912, such that the
controller 103
receives transmissions from the remote control device 32 and is. Capable of
implementing wireless requests from the remote control device. 31.
This
communication between the remote control device 32 and the vehicle 1.0: can
be.
established concurrently during charging of the rechargeable power source 180
at the
charging station 50, such that the pairing period and the charging period
overlap:. In
at least some embodiments the pairing period is less than or equal to the
churning
period.
1001391 .Additionally. the method 900 may include, at 91.4, displaying a slate
of
charge of the rechargeable power source 1.80 at the vehicle 10õ. e.g., at the
charging
station 50; wherein the state of charge of the rechargeable power source .180
may be
displayed at the vehicle 10 both when charging the rechargeable power source
180
and during use. of the remote control device 32, ;The state of charge of the
rethargeable power source 10 tnay be &played, for .exannpie, .via. a .series
alights,
each light, representing a level of a state of Charge of the rechargeable
power source
'180,
100.401 Fig, 22 is a flowchart of another example method 9:50 fOr charging. .a
remote control .device in accordance with the principles.of the present
inventionõSuch.
as the remote control. device 32 discussed herein, which comprises a .wireless
communication. system 456 including a wireless transmitter 1.78 (4., capable
of one
or twO-way communication), a rechargeable power source 1M, and at least one
.control (e.g.,. controls I 96A-C) that causes the wireless transmitter 178 to
wirelessly
.trarionit a. request to a. controller of a materials handling ychicle 10. As
used herein,
the term "control', when used to describe a control of the remote control
device. 32, is
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.meatit to include any :structure capable of providing the desired function,
including
hut not. limited: to buttons, switches, dials, etc.
1001411 The method 950 for charging a remote control device 32 begins at 952
by
initiating contact between a: component of the remote control device 32: and
an
element of a, :charging station 50, the charging station 50 located at the
vehicle 10, and
then sensing cOntaet between the remote COMT01 device component and the
Charging
station element. As described above, the remote control device 32 can include
one or
more charging contacts 210 that are each arranged: to engage a corresponding
charging element 320 of the charging station U. such that when they are
engaged, a
second presence contact 222 or a similar device engages a corresponding
presence
:Contact 212 to detect or sense that the charging contact(s) 210 and charging
element(s) 2.20 are in contact with one another. However, other components of
the
remote control device 32. and other elements of the charging Station 50 may be
used to:.
detectiserts.e the initiation of contact:
100 421 At 954, the carrot state Of charge of the rechargeable power Source
determined, Step 954 can be performed before or after step 952, i,e, the state
of
charge of the rechargeable power source 180 may be communicated to the
ebateing
station 50 both when the remote control device 32 is coupled to the charging
station
50, and during use of the remote control device 32 by the operator, as
discussed
herein,
1001431 Based on the current state of charge of the rechargeable power source
180
. and. alter step 9.52 is performed, at 956, a charging period is started,
wherein power is
supplied from the charging. station 50 to the rechargeable power source 1$0,
In one
exemplary embodiment, at step 958A, if the voltage of the rechargeable power
source
180 is below a voltage threshold VT, the charging station 50 charges the
rechargeable
power source 180 at a first, 'higher power level :PIA . According to this
embodiment,
at step 958B, if the voltage of the rechargeable power source 180 is above the
voltage
threshold VT, the charaing:station 50 charges the rechargeable power source
ISO: at a
second, lower power level P12. The resulting charging period in either ease,
i.e.,
step 958.A or step 958B, may be about the same, i.e., charging the
rechargeable power
source 180 up to the desired amount from above or below the volume threshold.
VT
may take about the same time. While only two power levels PL1 PL2 associated
with a single voltage threshold. VT are discussed herein, additional voltage
thresholds
and power levels could be used, wherein the charging period can always be
about the
36
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SoMe time regardless of the charge [eve" of the rechargeable power .source ISO-
when
it is inserted into the charging station 50. Additionally., an equation could
be used to
dynamically set the power level according to the current state of charge of
the
rechargeable power source 180.
1001441 ORCIV the charging period is complete, dna is, once the rechargeable
power
source 180 is charged to the desired amount, i.e., substantially fully
charged: or
charged to an amount less than a substantially full state of charge, e,g,õ
view- of the
sensed temperature if that technolotty is present in the system 8, or if less
than a full
charge is desired, the remote .control device 32 can be removed from the
charging
station SO,
1001451 Thus, the method of Fig. .22 continues, at 9:60, with -interrupting-
.contact:
between the remote control device component and the charging station element
and
sensing the interruption of the contact between the remote control. device
component
and the charging station element. As described above, the charging. -
contact(s). 210 of
remote control device 32 and the charging element(s) 220 of the charging
station
50 are arranged:such that as the two systems are disengaged, that state can be
detected
or .sensed, One example is the second presence oornaCt 222 that: can detect
when the
remote control device 32 is being removed from the charging station 5.0,
1001461 Finally, upon the sensing of this interruption at 960, or -upon the
rechargeable power source ISO being charged to the desired amount, the
charging
Station 50 can cease the supply of power from the charging station 50. to the
rechargeable power source 180 EA 962, thus ending the charging period.
1001471 The method 950 can include other optional steps shown in Fig. 22, For
example; the method 950 can also include confirming the establishment of
communication between the remote control device 32 and vehicle I 0 at
964õ.eg,õ With
a least one of an 'audible or visual queue. The method 9$0 an further include,
While
the remote control device component is in contact with the charging station
element,
establishing communication between the remote control device 32 and the
vehicle 10.
(eg., pairing) during a pairing period at 966, such. that the controller 103
receiVes
transmissions from the remote control device 32 and is capable of implementing
wireless, requests from the remote control device 32. This communication
between
the remote control device 32 and the vehicle. 10 can be established
concurrently
during. charging of the rechargeable power source 180 at the charging
station50, such
that the pairing period and the charging period overlap. In at least: .some
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embodiments, the pairing penod is less than of equal to the charging
petiokalihnutih
the pairing period may he greater than the charging period, as will he
discussed in
more detail below;
1001481 Additionally, the method 950 may include, at 968, displaying a aate of
charge of the rechargeable power source 180 at the Vehicle 10, 0,g., at the
charging
station 50, wherein the state of charge of the rechargeable power source 180
may be
displayed at the vehicle 10 both when charging the rechargeable power source
180
and during use of the remote control device 32. The state of charge of the
rechargeable power source 1$0 may be displayed, for example, via a series of
lights.
each light representing a level of a state of charge of the rechargeable power
source
180.
E00149l in accordance with an aspect of the invention, the charging period may
depend on the capacity of the rechargeable power source 180, the charge
rate/power
level supplied by the charging station 50, and/or the charge state of the
rechargeable
power source 1$0 When it is: inserted into the charging station 50. Thus, a
desired
charging period could be achieved regardless of the current state of charge of
the
rechargeable power source 180 when the remote control device 52 is placed in
the
charging station 50. For example, the current state of charge of the
rechargeable
power soiree 180 may be known to the vehicle 40, e.g., the state of charge of
the
rechargeable power source 180 may be communicated to the charging station 50,
as
discussed herein, The Charging station 50 may be instructed, e.g., by the
controller
103, to supply power to the rechargeable power source 180 at different rates
or levels
based on the state of charge of the rechargeable power source 180 when the
remote
control device 32 is placed in the charging station 50, so that the charging
period is
generally about the same time regardless of the state of charge of the
rechargeable
power source 180 when the remote control device 52 is placed in the charging.
slat:1On
50: For example, as discussed above with reference to steps 958,41B of fig, 2Z
if thw.
state of Charge of the rechargeable power source 180 is a first, lower state
of charge,
then a.flrst. greater rate/level of power may be supplied from the charging
station 50
to the rechargeable power source 1 8011 the state of charge of the
rechargeable power
source 180 is a second, higher state of charge, then a second, lesser
rate/level of
power may be supplied from the charging station 50 to the rechargeable power
source
180, The resulting charging period hi both cases could be about tbe same
time., e4.,
within about 0,5 seconds of the desired charging period. Any number of
rechargeable
38
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power source slats of charge and: corresponding rates/levela of power: :could
be
implemented such that the lime required to charge the_ rechargeable power
source 180
is within the desired charging period. Additionally, the usage life of the
rechargeable
power source 180 may he increased when it -is charged at a lower power level.
Hence,
an additional advantage of a consistent charging period as with the present
invention
is that the rechargeable power source 180 is sometimes charged at a lower
power
level, e.g., when the charge state of the rechargeable power source 180, when
it is
inserted ink) the charging station 50 is the second, higher state of charge
discussed
above. Hence, charging the rechargeable power source 180 at different power
levels
as discussed herein may increase the usage life of the rechargeable power
source 180.,
as opposed to if the rechameable power source 180 was charged at a consistent,
higher power level with each charge.
1001.50j Additionally, while the pairing period, which is
described herein as the
time period it takes to establish communication between the remote control
device 32
and the vehicle 10, may be less than or equal to the charging period, the
charging
period may also be less than the pairing period. As one example, it may be
determined that the rechargeable power source 180 does not need to be fully
charged
in order to operate for a desired use period. For example, a full charge of
the
rechargeable power source 180 may provide an operation time that is greater
than a
desired use period (e.g., an operator's shill), such that the rechargeable
power Source
180 does not need to be fully charged in order to be operable for the desired
use
period. In this case, the charging station 50 may he programmed to charge the
rechargeable power source 180 up to a less than full state of charge, which
would still
be sufficient for the remote control device to be operable for the entire
desired use
period. The time it takes to charge rechargeable power source 180 up to this
less than
full state or charge may be less than the pairing period. Other situations may
4.1.$0
occur where the charging period may be less than the pairing period:
[00151.1 With reference to Fig. 23, the principles of the present invention
can also
be implemented as a kit 1000 fbr retrofitting to a materials handling -vehicle
Kr in
Fig. 23, elements similar to or identical to those described above with
reference to
Figs. 1-22 include the same reference number followed by a prime symbol (f) An
element described with respect to Fig. 23 but not. specifically shown in Fig.
23 is
equivalent to the element having the same reference symbol as described above,
hut
without the prime symbol.
39
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100152f The vehicle 10' can include a vehicle controller 103' that is
responsive to
wireless requests. from an associated remote control deice: 32 that is .used
by an
operator interacting with the vehicle 10' similar to those types of vehicles
1.0 and
remote control devices. 32. described above An example kit 1000 would include
a
charging .statiou. 50' at. the vehicle 10', the charging station 50' for
charging a
reehargeable power source 18.(Y of the remote control device 32% wherein the
charging
station 50' is electrically coupled to a vehicle power source, and a receiver
:Wraith
as a BLE radio communicably coupled to the controller 103' of the vehicle
1Cri. In
particular, the charging station W' is configured such that the rechargeable
power
source 180'. is charged up to 6 desired amount (A full charge or less.than
lid! charge aS
discussed herein) atthe charging station .50.' within. a desired charging
period.
1001.53l The kit 1000 may further include a -pairing system 34' ..frir
establishing
communication between the remote. control device. 32' and. the vehicle 10',
such that
the controller 103' it capable of implementing wireless requests from the
remote
.control device 32.'õ The patting system $4' may, -far example, be similar to
pairing
system 34 and can implement the pairing algorithm(s) detailed in Fig,. 17
andlor
18.. Thus, the kit 1.000 can also include a pairing indicator, e.gõ, visual
indicator 42.4%
that confirms the establishment of communication betWeen the remote control
device
32' .and the vehicle 10'. Furthermore, the pairing system 34' can be
configured such
that the pairing period (a time period that it takes to establish.
communication between
the remote control device 32' and the vehicle 10') may be less than or equal
to the
charging period (a time period it takes to charge the rechargeable power
source 180'
to the desired amount). The pairing: period may also be greater than the
charging
period. The pairing system 34 may be incorporated into the charging. station
.50' or
may be a separate element.
1001.$41 It is contemplated that communication between the remote control
device
:32 and the vehicle 10' is established concurrently daring charging of the
rechargeable
power source 180' at the charging station 50', te.õ the pairing period and the
charging
period may overlap. Furthermore, in some embodiments, communication between
the
remote control device 32' and the vehicle 1.0', and charging of the
rechargeable power
source l80 at the charging station 50' are initiated with a single action.
For example,
the single action can comprise physically contacting a component: of the
remote
control device, for example, one or more. charging contacts 210 as described
above.
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with tn element of the charging station, for eutuple, one or. inure
Corfesponding
dnligint.-2. dements 220 as described above.
[001551 The remote control device 32' used ihi combination with theiit 1000
may
be the same as the remote control devices. 32 diSelosed herein. Hence, a
remote
control device manufactured. for use with a vehicle 10 including an Integrated
charging station 5.0 and related components could also be used with a kit 1000
for use
with an existing. vehicle 10'.
[001561 As described above with respect to the charging station 59, the
charging
station 50' of the kit 1000 can also include guide structure 420'. to align
the remote
control device 32 in the proper orientation for charging, the rechargeable
power
source 180',
E001.57i The kit .1000 cari also include an indicator (e,gõ. LEDs. 404, light,
.0i
similar structure) configurable to be attachable at the vehicle (Y for
indicating a.state
of charge Of the rechargeable power source I WV, The indicator can indicate
the state
of charge of the rechargeable power source I 80' both when charging the
rechargeable
power source 1 R0' at the charging station 50' and during use of the remote
control
device 32'. In some embodiments, the indicator comprises a series of Whs.,
each
hat representing a level of the state of charge of the rechargeable power
source 180%
1001.58i The kit 1000 includes at least one charging element 220' on the
charging
station 50' that engages at least one corresponding charging contact 2.10 of
the remote
control device 32% Furthennore, at least one of the. remote control device 32'
or the
charging station 50'. includes a presence contact 212' or 222' that detects
whether or
not at least one corresponding charging contact 210' and at least one charging
element
220' are correctly engaged with one another. If a correct engagement: is
detected, the
transfer of power to the rechargeable power source 180' of the remote
control:device
32 is ekohjed by the charging station 50?õ and ii a correct engagement is not
detected.,
the transfer of power to the rechargeable power source 180' is not enabled by
the
charging: station 50'. In at least some embodiments, the remote control
device.. 32'
comprises at: least two charging contacts 210' or at least lbur charging
contaCts 210'
that are positioneti to engage corresponding charging elements 220' on the
charging
station 50e,
100159) The arrangement of the remote control device 32' and the chargini.!
station
Sty of the kit 1000 is configured such that the presence contact 21.2' or 222'
indicates
the removal of the remote control device 32' from the charging station 50',
.Which
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ceases the transfer of power.to the re=Charweablie power source I80' from die
charging
station 50', before the at least one charging contact. 210' is disengaged
.froin the at
least one corresponding charging element 220'. Hence* the transfer of power
from the
charging Station 50' to the -rechargeable power source 180' is ceased before
the at least
one charging contact 210' is disengaged from the at least one corresponding
charging.
element 220',
100160i The kit 1000 may .also utilize contactless, or induction, charging in
Anti"
the rechargeable power source 1.80' of the remote control device 32 can be
Charged
by being in close proximity to or on the surface. of, a compatible induction
charging
station (not shown). Such an induction charging .station may he located, for
example,
in a driving or steering control of the vehicle 10' such that the rechargeable
power
source 180' may be charged while the operator is manually- driving the vehicle
10'
.from the operator's station 20'. The kit 1000 According to this aspect of the
invention
may be at least partially located in the. vehicle steering Control or other
vehicle
component that facilitates the comactlessiinduction charging of rechargeable
power
source .180', the rechargeable power source 180' may be charged by the
operator
grasping the driving/steering control,
1001.611 The kit 1000 may tthliie any of the other features and/or functions
of the
remote control device 32' and the charging station 50' described above for
Figs, 1-22,
his noted that if the vehicle 10' to be used With the kit 1.000 was previously
set up for
interacting, with a wireless remote control device, the controller logic in
the vehicle.
controller .103' may need to be updated to be used. with the kit 1000, and a
receiver
that was already provided at the. vehicle 10', i.e.., fox receiving wireless.
requests. from.
a remote Control device that was used with the vehicle 10' before the kit.
1000 was
installed on the vehicle 10% may be turned off in lieu of the receiver 102' of
the kit
1000, ie., for use with the remote connol device :32' alisociaW with the kit
1000:
1001.621 With reference now to Fig:. 24õ. a remote control device 32 in
aecordance
with an embodiment of the invention may be incorporated. into a glove garment
1100.
The use of the glove garment 1100 eliminates the need lbr the holding strap
190, and
the first control 196A may be provided, an a finger of the glove garment 11.00
as
opposed to being a part of the upper housing 174, but the remaining components
of
the remote control device 32 illustrated in Fig. 24 may he the same or Similar
to those
of the remote control device 32 of Figs. 4-7, including a shape of the portion
of the
upper housing 174 that engages with the charging station 50 at the vehicle 10.
Hence,
42
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the charging station 50 at he vthiele 10 may be the at.ine as the charging
station:. 50
described above, ie., since the charging station-engaging portion of the upper
housing
174 of the remote control device 32 incotporated into the glove garment 100
Can
have the same dimensions as the charging station-engaging portion of the upper
housing 174 of the remote control device 32 in the embodiment of figs, 4-7,
the same
charging station 50 could be used with either the finger-mounted remote
control
device 32 of Figs, 4-7, or the remote control device 32 incorporated into the -
glove
garment 1100 of Fig. 24.
1091631 If the remote control device 32 incorporated into the glove garment.
1100
were used. in combination with the inductive charging technology disclosed
herein,
inductive Charging structures may be incorporated, for example, into the palm
of the
glove garment 1100. Such charging Structures in the glove garment 1100 could
he
used with charging elements incorporated, for example, into a steering control
of a
vehicle paired to the remote control device 32., in which case a rechargeable
power
soarce of the remote control device 32 could be charged while the operator
isonsping
the, steering contra
1001641 According to additional aspects of the present. invention, there may
be
conditions and/or events that cause the vehicle 10 to become Unpaired flrom
the
remote control device 32., NA,herein a complete pairing process utilizing the
pairing
system 34, as described herein, may be required to re-pair the. vehicle 10
with the
remote control device 32. There may be other conditions or events that cause
the
vehicle 10 to become unpaired from the remote control device .32, 'wherein
something
other than a complete pairing process utilizing the pairing system 34, as
described
herein, may be required to re-pair the: vehicle. 1.0 with the remote control
device 32:
Several exemplary use cases with regard to Impairing and re-pairing will now
be
described.
[0011.651 A first exemplary use case may occur by powering down the vehicle
TO:
According to this. first use case, the remote control device 32 is unpaired
:from the
controller 10.3 and requires acomplete inning process utilizing the pairing
system 34,
as described herein, to re-pair the vehicle 10 with the remote control device
32... In
accordance with this exemplary first use case, a complete pairing process
utilizing the
pairing system 34 may be required to re-pair the remote control device. 32 to
the
vehicle to whenever the 'vehicle 10 is powered down:,
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IOW 661 A. ecortd empl ttry use caw t bay be sabstotially as de 'bed above
with
respect to Fig. 19, wherein the vehicle operator temporarily leaves :he
vehicle 10õ e.g.,
to take a break: The details of this second. exemplary use case are
discussednhove
with reference to Fig, 17 and. will not be repeated again.
001671 Third and fourth exemplary use cases may occur if no vehicle-related
activity takes. place her greater than a first predetermined amount of time
after
communication between the remote control device. 32 and the vehicle 10'is
established (third use case) or if no vehicle-related activity takes place for
less than
second predetermined amount of lime after communication between the remote
control device 3.2 and the vehicle 10 is established (fourth use case). The
details of
these third and fourth exemplary use cases are discussed above With reference
to Fig.
20 and will not be repeated again,
[001681 A number of exemplary use cases may arise whore multiple. remote
control
devices 32 and/or multiple vehicles 3.0 are concerned. In a fifth exemplary
ase-ease,
assume a first remote control device 32 is currently paired with. k.-1, first
vehicle 19, and
a second remote control device 32 is currently paired with a 5;erotici vehicle
M.Ji
this fifth use case, the first remote control device 32 is inserted into the
:chateing
station 50 of the second 'vehicle 10. Under this circumstance, the chanting
seetion.30:
of the second vehicle 10 may charge the rechargeable power source 180 of the
:first
remote control device .32, the first remote control device 32 may become
unpaired
from the first vehicle 10, and the second remote control device :32 may become
unpaired. from the second vehicle 10. The first remote control device $2 will
not be
paired to the ie:cort d vehicle 10 in the fifth use case.
100169j In a sixth exemplary use =case and with reference to Fig_ 24, assume a
remote control device 32. is currently paired with a first vehicle 10A Such
that the
remote control. device 32 wirelessly communicates with the first vehicle 10A,
and.
second vehicle 1013 is not currently paired with a. remote control device, in
this :sixth
use case, the remote control device 32 is paired with die second vehicle 1.0a
using a.
pairing process, for example, by hisellitig the remote control device 32 into
the
charging station 30 of the Second vehicle 1013, Using this pairing process,
the
charging anion 50 of the second vehicle 10B may charge the rechargeable power
source 180 of the remote control device 32, and the remote control device 32
may
become paired. with. the Seecynd vehicle 1013 such that the remote control
device
wirelessly communicates with the second ide lOB. This pairing process
may :also
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cause the remote control device to become unpaired..frorn the first vehicle
1.0A,
that the remote. control device no longer wirelessly. communicates. with die
first
vehicle 10A, Once the remote control device 32 is paired with the Second
vehide
1013 and. impaired from the first vehicle WA, the second vehicle Iff.13 may
respond to
remote requests from the remote control device 32, while the :first vehicle
10A may no
longer respond to remote requests from the remote control device 32.
1.001701 As described above, the wireless communication system 4% of the
=remote
control device 32 and/or the .BLE, radio 402 of the charging. station 50 .cart
be
configured, for example, to enter a low power mode when the remote control
.device
32 is being paired to the second vehicle 1.013 and/or the rechargeable power
.source
180 of the remote control. device 32 is being charged at the charging. station
50, e,g.,
to ensure that only a remote control d-eviee 32 that is within, a minimum
distance*
corresponding to the signal strength of the communications received from the
remote.
Control device 32, from the charging: station 50, is -recognized as the remote
control
device 32 for the second vehicle 10B to pair with
.1001711 According to the sixth exemplary use case, prior to the pairing
process., the
second vehicle 1013 may be sent, es., by a Warehouse Management:. System W.MS
in
communication with the second -vehicle 10B, to a designated location, such as,
for
exampleõ the location of the operator, the location of the first vehicle 10A.,
the end of
an aisle in which the operator and/or first. vehicle 1OA. are located, a
designated
waiting area, etc.. The second. vehicle 1013 may be an unloaded vehicle,. Leõ
:free from.
a load and thus ready to carry items to be picked. by the operator. The second
vehicle
1013 may be instructecj. to move to the designated location by the Warehouse
Management System WNIS,, for example, when the first vehicle WA is loaded with
a
desired amount of pick items and is ready to be sent to a. different location,
i.eõ a
location that jg different than the current location of the vehicle 10, such
as a loading
dock.1,1) or other location:where the pick items on the first vehicle 10A. are
to be sent
The operator may also request that the second vehicle 1013 be .sent to the
designated
location, .for .example., using 4 control on the first vehicle -110Aõ over a.
headset, etc..
Once the second vehicle 1013 paired to the remote control device 32, the
second
vehicle 10.13 may no longer implement commands from the Warehouse Management
.System WMS, such that the second vehicle 1013 will only implement wireless
commands from the remote can:0W device 32 with which it is paired.
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1001721 Once the :remote control. device 32 is onparred loin the fjrst.
yettiolelOA,
the Warehouse Management System WMS may send instructions to the first vehicle
OA to move to the loading dock
andior to another location, such as a vehicle
charging station (not shown), Using this sixth exemplary use case, an operator
may
quickly switch between vehicles 10A, 10B, resulting, in an ittemse in work
productivity and efficiency.
[001731 In aseventh exemplary use ease, assume a first remote control deviee
32 is
currently paired with a vehicle 0, and a second remote control device 32 is
not paired
with a vehicle in this seventh. use case, the second remote control. aeviCe.
32
inserted into the charging station 50 of the vehicle 10-. Under this.
circtunstanecõ the
charging station 50 of the vehicle 10 may charge the rechargeable power 3010Ct
180'
of the second remote control device. 32, the first remote Control device 32
May.
become unpaired from the vehicle 10, and the second remote control device .32
will
not be paired tt,-) the vehicle 10,
741
In an eighth exemplary use case, the. remote control device .32 is moved
out of range of the vehicle 10, ie., such that the wireless, transmitter 178
is no longer
able to communicate with the receiver 102 for a predetermined time, period,
According to the eighth use case, the remote control device 32 may become
unpaired
from the vehicle 10õAccording to the eighth use case, if the remote control
device 32.
moves back into range of the vehicle 10 after a predetermined time period, the
vehicle
.10 may need to be. shut down and restarted to pair with a -remote control
device :32
utiliAng the pairing system 34, including pairing with the previously-paired
remote
control device 32, or a different remote control device 32. If the remote
control
device :3.2 moves back into range of the vehicle 10 within the predetermined
time
period, the vehicle 10 may BM need to be shut down and restarted to pair with
the
previously paired remote control device 3.2> e,g., the previously paired
remote control
device 32 may be re-paired with the vehicle 10 by inserting the remote control
device.
$2 into the charging station 50 of the vehicle. Pairing the vehicle 10 to a
different
remote control device 32 may require a vehicle shut down and restart,
regardless of
how long the previously paired remote control device 3.2 was out of range of
the
vehicle 10,
100175) Additional exemplary use cases concerning pairing and/or charging
periods will now be described.
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100761 In a ainth exemplary use case, a desired charge stateõ.eg,,
sulistantially
hill charge state, of the rechargeable power source 180 can be achieved by
charging
the rechargeable power source 180 at the charging Station 50 in five seconds
or less.
According to this use case, the substantially -hal charge state of the
rechargeable
power source 1.80 may yield a use period of the remote control device 32 of at
least
eight hours.
1001771 IA a .tenth. exemplary use case, the charging station SO varies the
power
level supplied to the rechargeable power source 1:80 depending on the state or
thaTge
of the rechargeable power source I ki0. when the remote control device 32. is
inserted
into the charging station 50, as described. herein with respect to. Fit 22.. A
charging
period according to the tenth use case will always be about four seconds,
regardless of
the state of charge of the rechargeable power source 180 when the remote
control
device 32 is inserted into the charging station 50. Hence, a predictable
charging
period is achieved.
10(H 78 It is noted that the type of tralISITIOSIOTS. 4e1-1(
by the remote control device
32 to the vehicle 10, e.g., requests, such as travel requests, may be other
types .of
unnsmissions, .As one example,. the transmissions. may comprise location-based
transmissions that inform the controller 103 Of the vehicle 10 where the
remote
control device 32. is located relative to the vehicle ./0. 'These types of
location
transmissions may be used by the controller 1.03.õ e.g., to follow the remote
control
device .32. Hence, the vehicle 10 may follow an operator wearing, holding, or
carrying the remote control device 32. Such a remote control device 32 could
be
charged by the ehargins station 5Q and paired to the vehicle .10 as described
herein.
100791 In accordance with another aspect of the present invention, charging.
of the
rechargeable power source 180 by the charging station 50 may be disabled while
the
vehicle 10 is in motion. This aspect of the invention may, not apply to
inductive
charging of the rechargeable power source I 80:
1001801 Furthermore, when an operator is attempting to pair a remote, control
device 32 to a. vehicle 10 that is in communication. with the Warehouse
Management
System WMS., the Warehouse Management System \VMS can determine if one or
more remote control device operational checks have been performed within a
predetermined time period, tbr example,. within the last 12 hours, Such
operational
cheeks may include, for eiminple, .checks to ensure the operability of
controls of the
remote control device 32, such as the horn and/or brake. buttons 1978, 197C If
such
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operational check(s) have not been performed. within the prt.,,determined.
time period;
the vehicle 10 may communicate to the operator that operational check(s).
must: be
performed prior to the remote control .device 32 being pairable with the
vehicle 10;
i.eõ the remote control device 32 is only allowed, to pair with the vehicle 10
if the one
or more remote control device operational cheek; have been peribmied within
the
predetermined time period. The operational checks may be performed by the
operator
implementing the controls,
by holding down the horn and/or brake butions'19713,
197C.
int-1181i
Additionally, when an operator is attempting to pair a. remote control
device 32 to a vehicle i 0 that is in communication with the Warehouse
Management
System WMS, the Warehouse Management 'System WMS
determine if the
operator is authorized to operate the vehicle IV that the operatOr is
attempting to pair
to the remote control device 32. For example, vehicles that are to be used
only in. a
certain location, such as in a freezer, may only be pairable with remote
control
devices 32 where the operator will Use the vehicle in that location. As
another
.example, operators may be limited to operating certain vehicles. Remote
control
devices 32 in these: situationsmay only he authorized to pair with stieb
vehicles When
these condition(s).are met
[001821 in accordance with an aspect of the invention, the charge life of the
rechargeable power source 180 over a given operating cycle may be increased by
turning off or reducing the power consumption of one or more components.Of the
remote control device 32, e.g., the components of the wireless communication.
system
456 including the wireless transmitter 1.78, when an operator is determined to
be
'standing on the pIntforni 21 of the vehiclelp, es:, as detected by the
presence sensors
22.
[00.831 Tiw. terms "pairing" and "synchronizing" Os ttsed herein and in the
various patents and published patent applications incorporated by reference
herein)
are used interchangeably herein to describe a secure process whereby a
wireless
remote control device and vehicle controller identify each other as valid
command
and response devices..
Inal841 .A (Margin, station 1050 and a remote control device 1032 constructed
in
accordance with a still further aspect of the present disclosure are
illustrated in Figs.
26. und 27. Elements on the charging station 1050 which are generally the same
as
elements on the charging station 50 described above are referenced with the
same
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teterefiee ninna/415i used for those elements on the charging station SO.
Sbnilarly.
elements on the remote control device .1032. which are generally the same as
elements
on the remote control device 32 described above are referenced. with the same
reference numerals nsed for awe elements On the remote control device 32,
1001851 The charging station 1,050 comprises. a docking port 1052, which may
comprise a pocket or recess shaped to receive the remote control device 10.3.2
:stteh
that chargiik4 contacts 210 on the remote control device 1032 are õaligned
with and
engage with charging elements 220 at the Charging station 1.050 to effect
charging of a
rechargeable power source 180 forming part of the remote control device 1032,
it is
also contemplated that the remote control device 1032 may also interact With
the
docking port 1.052 to allow charging of the rechargeable powetsource 1,80 -
via: a non
contact charging operation, e.g.., inductive charging
1001861 The charging station. 1050 can comprise one or more visual indicators
that
convey information to an operator, which information may comprise one or more
of::
a charging state of the rechargeable power stmirce 180 when the remote control
device
1032 is coupled to the charging station 1050õ a charging state of the
rechargeable
power :source I:80 when the remote control device .1032 is removed, from the
charging
station 1050, a pairing status between the wearable remote control device 1032
and
the vehicle controller .103, and/or that the remote control device 1032 is
physically
connected to the charging. station 1050,
001871 in the embodiment illustrated in Figs. 26 and 27, a first visual
indicator
1060 and a second. visual indicator 1070 are provided, on the charging station
1050.
The first visual indicator 1060 may comprise one or more lights, such as
LEDs,. The
first -visual indicator 1060 ..rria'y be provided ptoximate to the docking
port 1052
defined within the charging station 1050, as viewed in.figs, 26 and 27, which
docking
port. 1052, as noted above, comprises a pocket or recess shaped to receive the
remote
coatrol device 1032. A. graphic 1014 may be provided. on the remote control
device
1.032 adjacent to a travel button 197A also provided on the remote control.
device
1032, see Fig, 26.õ which travel button. 197A may' cause a wireless
transmittea- 178
forming part of the remote control device 1032 to wirelessly transmit a
request :fOr a.
vehicle 10 to travel across a floor surface. The first visual indicator 1060
may be
Shaped to correspond to the graphic 1034 provided on the remote control device
1032
to aid a .user in positioning and connecting the remote control device 11032
to the
docking port 1052 of the chargin2, station 1050. In the illustrated
embodiment, the
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graphic. 1034 provided on the remote control. device 1032 is shaped as an
.t$osceles
triangle facing upward when the remote control device 1032 is coupled to the
charging station 1050, but could comprise any other geometric shape, image,
.icon,
etc, Also in the illustrated embodiment, the first visual indicator 060 is.
generally
shaped as an isosceles triangle pointing downward, but could comprise any
other
geometric shape, image, icon,. ete. The first visual indicator 1060 shaped as
a
downward facing: triangle provides an indication to: a user that the remote
control
device 1032 should be positioned relative to the docking port 1.052= such that
the
upward facing triangle 1.034 on the remote control device 1032 is positioned
adjacent
to the first visual indicator 1060 so as to mate with or mirror the first
visual indicator
1060.
1001.8811 The. second visual indicator 1070 may be positioned proximate to the
first
visual indicator 1060, such as just above the first visual indicator 1060 as
viewed in
Has,. 26 and 27. The second. visual indicator 1070 may be defined by a.
plurality of
linearly arranged lights, such. as LEDs, which may be activated individually
and
serially. The lights of the second visual indicator 1.070 May have a different
color
than the one or more lights of the first visual indicator 1060,
[001891 When 4 v chicle.10 comprising the charging station 1050 is powered
up,
turned from an OFF state to an ON state, the first visual indicator 1060 may
be
activated and, preferably, is pulsed ON and OFF to provide a. visual display
related to
inserting the wearable remote control device 1.032 into the docking port 1052,
'while
the second visual indicator 1070 remains OFF, see Fig: 28A. With the first
Visual
indicator 1060 activated, i.e., pulsed ON and OFF, and the second visual
indicator
1070 OFF, this indicates, to an operator that the charging station .1:050 is
enabled and
functional and she/he needs to couple the remote control device 1032. to the
docking
port '1052 of the charging station 1050 to effect .pairing and charging.. If
the .first
visual indicator IOW is not activated, this may indicate that the charging
station 1.050
is not enabled. Hence, the first visual indicator IWO and the second visual
indicator
1070 may be =figured to be activated independently of each other such that the
first
visual indicator 1060 may he activated while the second visual indicator 1070.
is not
activated.
100190] Once the remote control device 1032 has been physically connected to
the
docking port 1052 of the charging station 1050, the.. first yiu& indicator
1060 may. he
deactivated, turned OFF, and at least One of the tights defining the second
Visual
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indicator 1070 may be activated to convoy to the operator that: the relucltv
control
device 1012 has been physically connected to the docking port. 1052, see rig.
.28B.
Once docking of the remote control .device 1.032 has occurred, the remote
control
device 1032 will attempt to pair with the vehicle controller 103 and the
rechargeable
power source. 180 of die remote control device 103.2 will begin to be charged
by the
charging station 1050 Lights defining the second visual. indicator 1070 may he
activated serially, such as from. left to right as viewed in Figs. 26õ. 27 and
288.; to
indicate the status of the charging operation of the power source 180 or the
charging
state of the. rechargeable power source180 when coupled to the charging
station 1050.
Once the rechargeable power source 180 is fatly = charged, all lights defining
the
second indicator 1070 may be activated, turned ON, see Fig., 28C.
[001.9.1.1 .Figs. 29A ¨ Fig, 29C provide an alternative embodiment, as
Compared to
that of Figs.
28Cõ for the activating: and. deactivating of the first visual indicator
1060 and the second visual indicator 1070 during physical connection and
pairing of
the remote control device 1032. with the docking port 1052 of the: chargingY.
station:
1050, The embodiment of Figs, 29A ¨Fig 29C can be utilized. for all
charge/pair
cycles such as .an initial cycle after vehicle 10 iis powered ON from. an OFF
:state as
well as subsequent charge 'cycles occurring before vehicle .10 is powered OFF.
As
described above, when a vehicle 10 comprising the charging station 1050 is
powered
up, Lt., turned from an OFF state to an ON state, the first visual. indicator
1060 may
be activated and, preferably, is pulsed ON and OFF to provide a. visual
display related
to inserting the wearable remote control device 1032 into the docking port
1.052,
while the second visual indicator 1070 remains OFT, see Fig. 28.A and Fig.
.29A.
With the first visual indicator 1060 activated, i,eõ pulsed ON and OFF. And
the
second visual indicator 1070 .OFF, this indicates to an operator that the
charging
station 1050 is enabled. and functional and she/he needs to couple the
rentoteconnol
device 1032 to the docking port 1052 of the charging station 1050:to effect.
pairing
and Charging. Once the remote control device 1032 has been physically
connected to
the docking port 1052 of the charging station 1050, the first visual indicator
1060 may
remain activated so as to provide a steady-state ON display., and at least one
the
lights defining the second visual indicator 1070 rnay be activated to convey
to the
operator that the remote control device 1.032 has been physically connected to
the
docket port 1052, see 'Fig. 2913. Once docking of the rQmote control device
1032has
occurred, the remote control device 1032 will attempt to pair with the vehicle
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.controllet 103 arid the rechargeable power source 180 of the remote ..connol
device
103.2 will begin to he charged by the charging station 1050. Lights defining
the
second visual :indicator 1070 may be activated serially, such as from 'left to
right as
viewed in Figs, 26, 27, 2913 and 290,. to indicate the status of the charging
operation
of the power source 180 or the charging state of the rechargeable power source
.1.80
when coupled to the charging. station 1050. Once the rechargeable power
stnirce.180.
is ftilly Charged, all lights defining the second indicator 1070 may be
activated, Le:,
turned ON. and the first visual indicator 1060 may be deactivated, Leõ tutted
OFF,
$ee Fig: .29C,
f001921 Because the first visual indicator )060 remains activated, as Shown in
fig,
298, while the -rechargeable power source 180 is chargint'z, the first visual
indicator
1000 and the second visual indiCalOt 1070 both provide cues to the operator
that the
remote control device 1.032 should remain connected. with the charging station-
1.050.
and that charging of the rechargeable power source 180 is not complete until
the first
visual indicator 1060 is deactivated and all the lights of the second visual
indica&
1070 are activated, Le., see Fig 29e.
fO01931 In Fig. 288, Fig_ 28C.,. Fig. 2.913 and Fig, 29C, the individual
lights the
second visual indicator 1070 can become activated,: or turned on, one after
the other
which can be described, as making the second visual indicator 1070 "grow." As
noted
above, a desired charge state, e.gõ, a. substantially full charge state, of
the rechargeable
power source 180 can be achieved by charging the rechargeable power source -NO
at
the charging station in five 'seconds or less 11õ for example, the second iai
indicator 1070 has five (.14t.rete segments, or lights, a timing of the
"growing of the
second visual display 1070 can be configured .such that the time period
between
activating each of the live: lights is about one second 0-1- 54), such that
activation of
all of the lights, including the filTh light, indicates that the rechargeable
power source
is fittly charged. Alternatively, embodiments in accordance with the present
disclosure contemplate the tinting between activating each of the first four
5egment$.
LEDs, or lights of the second visual indicator 1070 can be about 1 seconds (+I-
5%)
and activating the fifth and -final segment occurs about 200ms. (41- 5%) after
activation of the previous,, or fourth, light. One benefit of having a non-
uniform
timing delay between activating the light segments of the second visual
indicator 1.070.
is 10 reduce the chance of an operator misunderstanding the lighting Wes,
removing
52
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the -remote control device 1032 too early, and thereby preventing a. full
Charge Of the
rechargeable power source '180.
[001941 In either embodiment involving the activation of the first visual
indicator
1060 Ct,e,., Figs. 28A 28C or Figs 29A. NCI,. if the rechargeable power source
1.80
cannot. be charged, then the first visual display 1060 may flash to pulse, ON
and OFF
to provide a visual display indicating an errOr, while the second visual.
display 1070 is
turned OFF, see Fig, 281. The error may be related to the rechargeable power
source
180, the charging station 1050 or both being defective. The rate at which the
first
visual indicator 1060 is 'flashed ON and OFF to indicate an error may vary in
frequency as compared to the rate at which the .first visual indicator 1060 is
pulsed
ON and OFF when the vehicle 10 is powered ill),
[001.95! As noted above, once the rechargeable power source In has been fully
charged, all lights of the second visual indicator 1070 may be activated. All
lights of
the second visual indicator 1070 may also be pulsed to provide the operator
with an
intermittent display as a cite to perform an action as a test to confirm that
the remote
control device 1032 is functional and can communicate to the vehicle .I0,
i,e,õ that
pairing has been successful The remote control device 1.032 may further
comprise.a
horn button 19713 and a broke button 197C, similar to the horn and brake
buttons=
1978, .197C provided on the remote control device 32., see Fig. 4. The action
as a lest
to confirm that the remote control device 32 is functional and can communicate
with
the vehicle may comprise pressing the horn button 19713 to determine if a horn
on the
vehicle 10 is activated and/or pressing the brake button 197C to determine if
brakes
On the vehicle are actuated. Once the test has been successfully completed,
all lights
ofthe second visual indicator 1070 may be activated. continuously -to define
.a.steady-
state display. Hence, the second visual indicator 1070 may define an
intermittent
display, a Meady...state display; or a display where less than all of the
lights are
activated, i.e., a partially filled display, based on the information to he
conveyed to
the operator/user, if the lest is not completed successfully; the urst visual
indicator
IOW may flash. or pulse ION and OFF to indicate an error, while the second
visual
indicator 1070 is turned. OFF, see Fig,. 281. The error may occur due to
pairing
between the remote control device 1032 and the vehicle controller 103 not
occurring
success lallyõ The rate at which the first visual indicator I KO is flashed or
pulsed ON
and OFF to indicate that the test was not completed successfully may vary in
53
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frequency front when the first visual indicator 1060 is pulsed ON and OFF
when. Eh
vehicle .10is powered up.
[00196.1 As noted above, after the vehicle has been turned OFF and ON, the
rechargeable power source 180 successfully fully charged and the
test is
successfully com.pleted, all lights of the second visual indicator 1070 tiny
be activated
cOntintiously to define a steady-state display,. If, after the rechargeable
power source
.I.80 has been successfully fully charred and the test has been successfully
completed,
Operation of the vehicle 10 and the remote conitol device 1032 cause the
rechargeable
power source 18.0 to consume some of its charge such that the operator, before
the
vehicle is turned OFF,. again connects. the remote control device 1032 to the
docket
port 1052 for charging. After charging, the second visual indicator 1070 may
not
pulse to cue the operator to perform the test even though the rechargeable
power
source 180 may again reach full charge. Because the vehicle 10 has not been
turned
OFF and back ON. since the last successful test, the second visual indicator
IMO may
not be pulsed to cue the operator to perform the test again but instead,
retuttin...in its
steady state display indicating the rechargeable power source 180 is -fully
charged.
!Mtn Once the rechargeable power source 180 has been fully charged and the
-test has been completed successfully, which indicates that pairing has been
completed
successfully; the -first visual indicator 1060 may remain OFF and all lights
of the
.second visual. indicator 1070 may remain ON to define a steady-state display.
When
the first and second visual indicators. 1060 and 1070 are in these. states,
see Fig, 284,
this may indicate to the operator that a pairing status between the remote
control
device 1032 and the vehicle controller 103 is positive and active and the
vehicle 10
.May be operated via the remote control device 1032. During use of the remote
control
device 1032. to operate the vehicle 10, the rechargeable power source 180 will
lose
charge over Timm, which will be indicated by die second. visual indicator
1070, 1õe,
lights extending from right to lei : as viewed in Figs; 26, 27 and 28F win be
deactivated or turned OFF, to indicate the decreasing. level of charge of the
power
source 180 when the -remote control device .1.032 is not coupled to the
charging 'stalii.ni
.1050. When the charge is low, only a single light of the second visual
indicator 1070
may be activated and the first visual indicator 1060 may be turned ON to
provide u
steady-state display signaling; the operator that she/he needs to charge the
power
source 180* see Fig, 28a Hence* the first visual indicator 1060 may define an
intermittent display; see Figs. .2&A and 18I, or a steady-state display, see
Figs ; 280
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and 29B, it is EINO noted that the first and second visual: indicators .1.060
am/A.070,
*hen activated' as illustrated. in Fig. 28G, both provide steady state
displays. When
the: charge on the rechargeable power source 4.80 has been depleted, the
second visual
indicator 1070 may be turned OFF and the first visual indicator 1060 may be
pulsed
to indicate to the operator that the power source. 180 needs to be charged,
see fig,
2811.
1001981 As noted above, the rate at winch the first visual indicator 1060 is
.flashed
ON and OFF' to indicate an error may be at a different frequency as compared
to the
rate at which the first visual indicator 1060 is pulsed ON and OFF when. the
vehicle
.10 is powered up. The error may, for example, relate to an error with the
charging
station 1050 such that it is unable to charge the remote control device 1032.
The error
may also, for example, relate to an error with the remote control device 1032
or its
power source 180 such that it is. unable to receive, a charge from the
chargingstation
1050. Furthermore, the error may, for example, involve both the charging
station
1050 and the remote control device 1012 such that there are communication
messages
between the two devices that are not being received by the intended recipient
of the
communication message.
1001.991 As noted, the second visual indicator 1070 when activated can provide
one
of an intermittent display, as shown in the example of Fig, ND,. which may
indicate
to an operator to perform an action, or a steady-state display as shown in
the. example
offig. 28E, which may indicate to an operator that. the remote control device.
1.032 is
fully ready to use.
1002001 Also, when the first visual indicator 1060 and the second indicator
1070
are co-roan-runty activated, the first visual indicator 1.060 and the second
visual 1.070
can each provide respective steady-state displays. as shown in the. example of
fig,
28O., Which can indicate that the rechargeable power source: 180 has a low
charge..
[00011 In the example offk 28A, the first visual indicator 1060 may pnlse as-a
way to define a. visual display related to inserting the wearable remote
control device
1032. into the charging station 1050_
1002021 As noted above, the example of Fig,. 281 includes the lust visual
indicator
flashin4 so. as to provide a display indicative of the occurrence of some
error. Thisi6
only an example and, more .ttenerally, at least one embodiment of the present
disclosure contemplithis that the first visual indicator 1060 or the second
visual
indicator 1070 can, either individually or in combination with one another,
pnwide
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visual display related to a charging error occurring with the Chaisino station
050 or
the rechargeable power source MS.
[002031 As noted above, the example of Fig:. 281 includes the first visual
indicator
1060 flashing so as to provide a display- indicative of the occurrence of some
error.
This is only an. example and, more generally, at least one embodiment of the
present
disclosure contemplates that the first visual indicator 1060 or the second
visual
indicator 1070 can, either individually or in combination with. one another,
provide a
'visual display related to a pairing error occurring between the wearable
remote control
device 102 and the vehicle 10. As explained earlier, the term ''pairing" .(as
used
herein) d.escribes a Secure process whereby the wireless remote control device
1032
and vehicle controller 103 identify each other as valid command and response
deviceS. A pairing error can occur as the two devices try to initially pair
with one
another and fail or a pairing error can occur after a successful pairing such
that the
pairing is somehow interrupted or lost
f0412041 As noted above, the example of Fig, 210 includes the first Visual
indica/Or
1060 -flashing SO as to provide a display indicative of the occurrence of
.some error.
This is only an example and, more generally, at least one embodiment. of the
present
disclosure contemplates that the first visual indicator 1060 Or seCondNisnal
indicator
1070 can, either individually or in combination with one another, provide a -
visual
display related to a communication error occurring between the wearable remote
control device 1032 and the controller 103. Once. paired, the remote control
device
1032 and the controller .1.03 both act as senders and receivers of messages
passed
'between the two according to a predetermined communications protocol.
Communication errors can include, for example, when one of the devices does
not
receive an expected message.
[000$) Having thus described the invention of the present application in
detail, and
by reference. to embodiments thereof, it will be apparent that modifications
and
variations are possible without departing from the scope of the invention
defined In
the appended
56
CA 03187922 2023- 1- 31
