Case Study: Materials Handling

Industry: Materials Handling
Vehicles: Forklifts
Vision Solution: Custom designed multi-camera installation

Objective of Installation:
To provide forklift operators with a clear vision of the four gabbing jaws on a forklift attachment, used to pick orders. When picking and packing stacks of wire mesh for delivery, forklift drivers were operating with impaired vision. This resulted in a high rate of damaged product, which affected the sale ability of stock, leading to stock write-downs and margin erosion.

A multi-camera system was required; one that was adaptable enough to operate within a confined space and within the mechanisms of a forklift mast. The installation of a vision solution provided the customer with productivity gains and delivered cost benefits.

Design Considerations:
Each forklift has an attachment to the forklift mast that holds 4 gabbing jaws. Operators need to accurately line these jaws up with the grab points on a stack of wire mesh. Without a camera system the operator cannot clearly see all 4 grab points at the same time.

Essential considerations for this project included the available mounting locations for cameras, a requirement for mirror and true image perspectives and narrow camera angles. A large 10.2” monitor provided the operator with a split screen view of the 4 camera angles. Cameras positioned for rear perspectives, transfer a mirror image to the monitor for easier operating of jaws to the left and right. While a close-up perspective of the gabbing jaws allows simpler alignment of the 4 jaws with the grab points on mesh stacks.

Build Considerations:
The forklifts are multi-purpose and the attachment holding the 4 gabbing jaws needs to be removed when not in use. This required a simple connection point for camera cables, between the forklift mast and the gabbing jaw attachment. The connection needed to be robust, to withstand regularly handling.

The forklift mast is removed when the forklift is transported to other locations. This required an additional connection point between the fork and the mast. Due to the number of connection points and the support requirements for a 4-camera system, simplicity was key to the cabling set-up; for ease of use and servicing.

Rather than working with 4 camera cables, Truck Rear Vision Systems customised the wiring to allow two cameras to share wiring within a single cable. Only two cables were then required on the telescoping mast of the forklifts. This worked well with the limited space of the mast.

The connection from the forklift mast to the gabbing jaws’ attachment utilized heavy duty suzi coil, as used to connect prime movers and semi-trailers in the heavy transport industry. The plugs and sockets are robust, easy to handle for fitting or removing the attachment and offered enough connections to suit the installation.

Installation:
The camera system was fitted when the forklift was at the OEM’s dealer, prior to delivery to the customer. Each component of the system was installed separately, for easy assembly on site.

The 10.2” monitor was installed on the fork truck with associated wiring and cable connections. Then the hybrid 2-cable system was fitted through the mast, with special attention paid to setting and adjusting the cable tension. The objective was to provide enough tension for the cable to remain taught and out of the way, as the mast telescopes, while not over tensioning the cable and damaging the integrity of any wiring. TRVS has a special, heavy duty cable manufactured to specification, to ensure longevity in such applications.

Cameras are then mounted on the attachment. They are fitted and adjusted using a test monitor to check, compare and secure the relative camera views. This ensures the system plugs directly into the monitor once the forklift is assembled on site and is ready to operate.

To ensure hassle free assembly on site or when the forklift is dismantled for transport, all cables are labelled for easy identification. This allows anyone to connect the system quickly and easily. Attention to detail during the design and installation stages resulted in hassle-free on site assembly and an operating system that did not require additional fine tuning.

The TRVS’ specialty is custom vision solutions with very specific fit-for-purpose requirements. To discuss your business requirements, contact us admin@truckrearvision.com.au