DE202014009903U1 - Training and training simulator - Google Patents

Abstract

Training and training simulator for industrial trucks, characterized in that this with
a) a three-dimensionally movable computer-controllable frame platform mechanism (2) with 6-axis motion system,
b) an operator computer (9) and a main computer (16) with five rendering clients (17, 17a, 17b, 17c, 17d)) for the realistic representation of various realistic scenarios, such as
Loading and unloading operations,
Storage systems with tipping racks and high-bay warehouses,
Traffic management, behavior in dangerous situations
and representation of industrial trucks as well as a realistic physical representation of the industrial truck environment inside and outside the driver's cab as well as for performance measurement and evaluation of the completed training,
c) different guide stands / cockpits (11) to be arranged modularly on the frame platform mechanism (2) and / or original industrial trucks,
d) a frame (15), as the driver's cab / cockpit (11) enclosing cabin with transparent or white opaque cabin walls and cabin ceiling, including the front door (4), as projection screens for an environmental representation,
e) a computer-controlled projection system having at least five projectors (6, 6a, 6b, 6c, 6d) arranged outside or inside the cabin and rendering clients (17, 17a, 17b, 17c, 17d) and filters 19, 19a, 19b, 19c, 19d) with projection direction directly or via deflection mirrors (1, 1a, 1b, 1c, 1d) on the cabin walls and the cabin ceiling,
f) a head tracking device (13) as a vision system for the industrial truck driver, which is connected together with an image generator,
g) a transmitter (8) to be affixed to the body of the industrial truck driver and / or a camera with a focus directed towards the industrial truck driver, the transmitter (8) or the camera being connected to and communicating with several receivers on the projection system,
h) simulation of movement, acceleration or deceleration of the industrial truck by driving the frame platform mechanism (2) of the movement system by means of operator computer (9) and main computer (16),
whereby the acceleration is simulated by the driver's cab tilting backwards and the delay by tilting the driver's cab forward, as well as cornering and load changes by changing the charge,
i) simulation of cornering by continuation of the rotational movement via the vision system with at least two actuators for generating vertical and horizontal movements, wherein the motion system triggers a "thrusting effect" and then imperceptibly returns to the starting position,
j) a software for recording environmental views on the projection surfaces of the cabin walls of the frame (15) via the projectors (6, 6a, 6b, 6c, 6d) with the Renderclienten (17, 17a, 17b, 17c, 17d) all around and up as well as movement, visual and reaction processes in the simulation system, ...

Description

The invention relates to a training and training simulator for operating personnel, such as industrial trucks guiding forklifts and other industrial trucks, for training and education purposes in the logistics sector of companies and driving schools.

Known is a PC software "Forklift Simulator 2009" with forklifts from STILL. The disadvantage is that thus no realistic control by means of steering wheel or joystick is possible. This is completely unsuitable for training and training purposes of operating personnel (Astragon Computer Games GmbH, Mönchengladbach).

Also known is an interactive research and development simulator for mobile work machines, in particular for driving dynamics assessment of heavy construction machinery, in which the respective driver's cabs are installed in the simulator. The simulator platform is arranged on a movement system, which realistically simulates the movements, accelerations and decelerations occurring during operation and is surrounded by a curved projection surface for the environmental representation. The disadvantage is that this simulator is only stationary and is only suitable for research and development purposes of industrial and research institutions, but not for the training and education of. Operating personnel for industrial trucks (manufacturer: EADS / Dornier GmbH Friedrichshafen, location Technical University of Dresden).

Also known is a training station for training road vehicle drivers, which however is not suitable for the training and training of industrial trucks ( EP 0 836 169 A1 ).

Also known is a driver, exercise and testing device for operators of heavy, large or complicated vehicles, such as trucks with trailers, buses, military vehicles, etc.

This tester is also unsuitable for the operators of industrial trucks ( DE 690 25 535 T2 ).

The object of the invention is to provide a simulator for the training and training of forklift leaders and other industrial trucks as well as for lorries and reach trucks under real conditions, especially in relation to dangerous situations. In order to meet all requirements, in addition to original input devices different technologies should be used and combined to realize a high degree of reality. The trainee truck driver should find himself close to reality in the working environment in which he will actually work. The simulator should not be stationary but mobile. The operator station should be able to be integrated in the simulator by means of an original truck or a simulated operator station should be arranged in the simulator.

• a) einer dreidimensional beweglichen computersteuerbaren Rahmenplattform mit 6-achsigem Bewegungssystem,
• b) einem Operatorcomputer und einen Hauptcomputer mit fünf Renderclients zur realitätsnahen Darstellung von verschiedenen realitätsnahen Szenarien, wie Be- und Endladungsvorgängen, Lagersystemen mit Kippgestellen und Hochregallagern, Verkehrsmanagement, Verhalten in Gefahrensituationen und Darstellung von Flurförderzeugen sowie einer realitätsnahen physikalischen Darstellung der Flurförderzeugführer-Umgebung innerhalb und außerhalb des Führerstandes sowie zur Leistungsmessung und zur Auswertung des absolvierten Trainings,
• c) auf der Rahmenplattform modular anzuordnender unterschiedlicher modularer Führerstände/Cockpits und/oder originaler Flurförderzeuge,
• d) einer den Führerstand umschließenden Kabine als Rahmengestell mit transparenten oder weißen opaken Kabinenwänden und Kabinendecke, inclusive Eingangstür, als Projektionsflächen für eine Umgebungsdarstellung
• e) einem computergesteuerten Projektionssystem mit mindestens fünf, außerhalb oder innerhalb der Kabine angeordneten Projektoren mit Projektionsrichtung direkt oder über Umlenkspiegel auf die Kabinenwände und Kabinendecke sowie je einem Projektor zugeordneten Renderclient mit Filter,
• f) einem Headtracking-Gerät mit Sender und Empfänger als Sichtsystem für den Flurförderzeugführer, welches mit einem Image-Generator zusammen geschaltet ist,
• g) einem am Körper des Flurförderzeugführers anzubringenden Sender und/oder einer Kamera mit auf den Flurförderzeugführer gerichteten Fokus, wobei der Sender oder die Kamera mit mehreren Empfängern am Projektionssystem zusammen geschaltet ist und mit diesen kommuniziert,
• h) Simulation von Bewegung, Beschleunigung oder Verzögerung des Flurförderzeuges durch Ansteuerung der Rahmenplattformmechanik mittels Hauptcomputer und Operatorcomputer, wobei die Beschleunigung durch nach hinten kippen des Führerstandes und die Verzögerung durch nach vorn kippen des Führerstandes sowie Kurvenfahrt und Lastwechsel durch Ladungsveränderung simuliert wird,
• i) Simulation von Kurvenfahrt durch Weiterführung der Drehbewegung über das Sichtsystem mit mindestens zwei Aktuatoren zur Generierung von vertikalen und horizontalen Bewegungen, wobei das Bewegungssystem einen „Anschubs-Effekt” auslöst und dann unmerklich in die Ausgangslage zurück kehrt,
• j) einer Software zur Einspielung von Umgebungsansichten auf die Projektionsflächen der Kabinenwandungen über die Projektoren rundum und nach oben sowie Bewegungs-, Sicht- und Reaktionsabläufen in das Simulationssystem,
• k) einer Kamera zur Aufnahme in Verfolgerperspektive, dem damit zusammen geschalteten Operator-Computer und einer Auswertungssoftware zur Beurteilung des Szenariums und einer Leistungsbewertung des Flurförderzeugführers,
• l) einem System mit haptischer Rückmeldung von Transportkontakten, Kollisionen und Fahrbahnunebenheiten,
• m) einem Auswertplatz mit Operationscomputer und mindestens einem Monitor sowie
• n) einem Audiosystem zur Flurförderzeugführerinformation

gestaltet.According to the driving simulator for training and training of industrial trucks with

• a) a three-dimensional mobile computer-controllable frame platform with 6-axis motion system,
• b) an operator computer and a main computer with five rendering clients for realistic representation of various realistic scenarios, such as loading and unloading operations, storage systems with tipping and high-bay warehouses, traffic management, behavior in dangerous situations and representation of industrial trucks and a realistic physical representation of the industrial truck environment within and outside the driver's cab, as well as to measure the performance and to evaluate the completed training,
• c) different modular driver's cabs / cockpits to be modularly arranged on the frame platform and / or original industrial trucks;
• d) a cabin enclosing the driver's cab as a frame with transparent or white opaque cabin walls and cabin ceiling, including the front door, as a projection for an environment representation
• e) a computer-controlled projection system with at least five projectors arranged outside or inside the cabin, with projection direction directly or via deflecting mirrors to the cabin walls and car ceiling, and to a render client with filter assigned to each projector,
• f) a head tracking device with transmitter and receiver as a vision system for the industrial truck driver, which is connected together with an image generator,
• g) a transmitter to be mounted on the body of the industrial truck and / or a camera with a focus directed at the industrial truck driver, the transmitter or the camera being connected to and communicating with a plurality of receivers on the projection system,
• h) simulation of movement, acceleration or deceleration of the truck by driving the frame platform mechanics by means of main computer and operator computer, wherein the acceleration is simulated by tilting back of the cab and the delay by tilting forward of the cab and cornering and load changes by charge change
• i) simulation of cornering by continuation of the rotational movement via the vision system with at least two actuators for generating vertical and horizontal movements, wherein the motion system triggers a "thrusting effect" and then imperceptibly returns to the starting position,
• j) a software for recording environmental views on the projection surfaces of the cabin walls via the projectors all around and upwards as well as movement, visual and reaction sequences in the simulation system,
• k) a camera for recording in pursuit perspective, the interconnected operator computer and an evaluation software for assessing the scenario and a performance evaluation of the industrial truck driver,
• l) a system with haptic feedback of transport contacts, collisions and road bumps,
• m) an evaluation station with operation computer and at least one monitor as well
• n) an audio system for industrial truck driver information

designed.

All hardware is programmed with suitable software, computer peripherals, modules and components of the training and training simulator are interconnected in block diagram so that an optimal simulation of the operating state is feasible. By means of an associated software different realistic scenarios can be initiated, like the representation of
Loading and unloading of trucks, containers, transport trains, conveyor belts and / or
Dealing with modern storage systems such as tipping racks, high-bay warehouses etc.,
Dealing with process management systems and traffic management as well as container management,
Behavior in dangerous situations, process training. or the representation of various types of forklifts and trucks, such as forklifts, lane vehicles, reach trucks and
the performance measurement and evaluation of completed training units of the industrial truck driver including evaluation system.

The training and training simulator is mobile, d. H. designed portable and can be set up as needed. Both an industrial truck operator's replica and an original truck with sensory coupling to the operator computer and the main computer can be installed on the frame platform.

To lock the to be placed on the frame platform of the movement system for industrial trucks or original trucks different adapters are arranged there.

According to the invention, it is advantageous to control a 5-page CAVE projection by means of a VR software and thus to distribute the projections individually to 5 render clients. An integrated camera matrix always ensures a precisely fitting transition of the individual projection screens, so that it is possible to vary the number of projection screens and to individually adjust the number of training programs.

The headtracking system ensures that the perspective dynamically adapts from the truck's point of view, thus avoiding disturbing distortions and perspective errors.

The six-axis motion system is connected to the VR software via Ethernet interfaces in such a way that not only acceleration forces but also road bumps, collisions, weight shifts and loads on the truck are transferred to the feel of the industrial truck driver.

With the integrated into the VR software physics model is a very realistic simulation of the driving physics of industrial trucks feasible, as it is still possible in any known simulator.

The invention will be explained with reference to an embodiment. In the accompanying drawing are with

1 a training and training simulator in perspective view and with

2 such a simulator in backward view and with

3 Such a simulator in side view and with

4 Such a simulator in plan view and with

5 a block diagram of the simulator control shown schematically.

example

The training and training simulator consists essentially of the frame 15 , with the projection walls, the ceiling and the frame platform mechanics 2 Forming a closed cabin. Inside the cabin is as a cab / cockpit 11 an original forklift on the Frame platform mechanics 2 by means of the adapter 14 placed. On the projection surfaces are the projectors 6 to 6d via deflecting mirrors 1 to 1d directed. The controls of the forklift, the frame platform mechanics 2 as well as the projectors 6 to 6a are with the main computer as well as the operator computer 9 at the evaluation place 9 switched together. The frame platform mechanics 2 as well as the projectors 6 to 6d are controllable by means of special software, whereby the projection signals are each from the rendering clients 17 - 17d and the filters 19 - 19d be prepared. In the simulator, the industrial truck driver finds himself in his usual or future work environment, in which he actually works.

In function of the training and training simulator will be in the main computer 16 the same calculated by the software all operating conditions and the inputs of steering, gas, input devices and the head tracking system 12 . 13 also calculated with and on the rendering clients 17 - 17d distributed. The rendering clients 17 - 17d so get all relevant position data from the main computer 16 synchronized via Ethernet and then calculate the representation on the projection screen, including the sound reproduction via the audio system 20 of the training and training simulator.

About the operator computer 9 the trainer can select the scenarios and control entire systems.

The main computer 16 also transmits the physics data synchronized to the Motion Control via Ethernet 18 , This translates the physics data signals into the path and velocities for the six actuators of the frame platform mechanics 2 , which calculates from this a realistic movement of the driver's cab and reports as feedback to the driver.

The operator computer 9 is connected to the system and serves in particular for controlling all components from the evaluation station. He has three monitors 3 . 3a . 3b which are switched so that with
monitor 3
the motion control 18 is operated, as is turned on and off, and with
monitor 3a
the simulation software is operated, various scenarios are loaded, the motion control 18 is activated or deactivated as well as an intervention in the entire scenario is possible and with
monitor 3b
the visual representation takes place and this can be changed arbitrarily z. B. bird's eye view,
the replay function as well
the evaluation function is feasible.

All functions are handled by the operator computer 9 monitored and stored.

projection

The optimal vision system for the modular design of the training simulator is suitable for all industrial trucks and tugger trains. By means of the CAVE projection, the entire traffic situation in front, behind and next to the vehicle is always present when driving industrial trucks, as well as in the case of tugger trains.

The driver is completely surrounded by the 3D environment and thus becomes part of the virtual environment.

In addition to the complete all-round view is an upward view, through the 5-sided CAVE projection with variable side adjustment by the operator computer 9 and the main computer 16 guaranteed. A total of 6 projectors are used with a resolution of 2400px × 1050px (SXGA +). To enter the simulator is the entire rear projection screen 4 by means of a roller rail 5 displaceable.

Head tracking

The head tracker 12 . 13 is a device that detects the position, position and movements of the head of the truck to provide a representation corresponding to the viewing angle or derive other positions from it. Through head tracking 12 . 13 A camera is controlled by actuators and the camera image is displayed on a display.

If the observer (industrial truck driver) looks to the left, the camera automatically moves to the left as well.

If the viewer looks to the right, the camera automatically moves to the right. The use of a head tracking system allows the industrial truck operator to view the virtual simulation environment in perspective and to look past the cargo or other obstructions. This is possible without head tracking neither in 2D nor in 3D projections. The position of the truck driver in relation to the virtual space is the operator computer 9 and the main computer 16 (Image generator) known at any time. The driver position is determined by means of an infrared transmitter 8th , This infrared transmitter 8th communicates with multiple infrared receivers 12 the on the handle of a headset on Headtracking device 13 are mounted, which carries the industrial truck driver. In dependency of Head position calculates the skin computer 16 the 3D representation on the five projection surfaces so that the perspective for the driver on all projection surfaces is shown perspectively correct and distortion-free.

movement system

The 6-axis motion system of the frame platform mechanics 2 The simulator is an elementary part of the whole simulation. Together with the CAVE projection, the audio system 20 , the audiovisual impressions and the real controls for haptic sensation, the motion system significantly amplifies the proprioceptive sensation, such as perception of body posture and movement in space as well as the degree of realism. The interplay of audiovisual information about eye and ear, haptics, perception of the position and movement of the body in space and the detection of acceleration and deceleration processes by the vestibular system result in the overall impression to be simulated.

Accelerating and decelerating while driving is one of the horizontal movement changes. When accelerating the weight of the truck driver is increased and pushes the body of the same in the seat or the cab / cockpit 11 , When braking, the truck driver is out of the seat or driver's cab / cockpit 11 lifted. In the simulation, horizontal forces are represented by the longitudinal inclination of the simulator. During acceleration, the simulator is raised in front, so that the horizontal acceleration movement is simulated by gravity. The direction of force acting on the truck driver corresponds to the direction of force when accelerating, but is generated by gravity. When decelerating, the direction of force is reversed. Ramps, inclines or bumps result in vertical movement changes. These are simulated 1: 1. When cornering, the driver also feels a significant impression of the change in movement. In the simulator, the impression of an incipient movement change is triggered, since the human being can not distinguish a subsequent uniform movement from a stationary situation. The continuation of the rotary motion via the sight system creates an impression of cornering. The movement system "pushes" the simulator in the appropriate direction and returns below the threshold of perception of the human in the starting position in order to have the maximum leeway for a new movement. For optimal simulation of truck operating conditions, especially of forklifts, reach trucks and tugger trains is the specially adapted, six-axle Rahmeplattformmechanik 2 of the movement system. By combining the six actuators of the same, the entire range of possible movements is simulated. The movement system 7 is connected and connected to the software via an Ethernet interface, so that not only acceleration forces, road bumps and collisions, but also weight transfers and loads on the industrial truck driver are transmitted. Different physical properties due to the load condition of the truck are integrated into the software for each truck and have an effect on the truck's 3D model. If the load is heavy, it simulates "the truck gets to its knees", the load is picked up incorrectly and the center of gravity shifts to outside the stability limit, simulating "the truck tilts over the respective tipping edge". All of these effects are transmitted in combination to the motion system so that the truck driver experiences direct feedback.

If he takes on a heavy or unevenly distributed load, the movement system senses this center of gravity displacement.

If the load is too heavy, the truck tilts forward. All values and sizes are realistic, so that the inclination in path and intensity of the recorded load corresponds. This means that the center of gravity shift of the truck is clearly noticeable in the simulator.

Interchangeable bodies (modular design)

On the frame platform mechanics 2 of the motion system is a selected adapter 14 located, which the arrangement of different trucks and replicas of their cabs on the frame platform mechanics 2 by means of a trolley 10 allows.

The communication between the original input devices and the software takes place via the CanBus, which is provided by the manufacturer in the input devices.

software

The software is designed so that the depicted environments are interchangeable and customizable. The exercise units are divided into scenarios for each truck, which can be selected individually and separately depending on the exercise level.

The individual scenarios are provided with a point system to enable a performance evaluation of the truck drivers. The evaluation software is located on the operator computer 9 at the evaluation place.

The ride is tracked by a separate camera and can then be replayed on one of the monitors 3 - 3b be considered. An evaluation algorithm, based on a defined point system, adds collisions, content errors and a time bonus to perform a performance evaluation at the end of each simulation. The simulations are stored in log files and assigned to the individual industrial truck drivers. To further optimize the simulation, free "events" are to be triggered via the selection menu. This way, suddenly appearing road users can be switched on and off or dangerous situations can be displayed.

LIST OF REFERENCE NUMBERS

1, 1a, 1b, 1c, 1d

deflecting

2

Frame platform mechanics with motion system

3, 3a, 3b

(Monitor, replay)

4

rear sliding door (projection screen)

5

roll bar

6, 6a, 6b, 6c, 6d

projector

7

movement system

8th

Head tracking infrared transmitter

9

Operator Computers / Auswertplatz

10

Trolley for driver's cab (module)

11

Driver's cab / cockpit (module)

12

Head tracking infrared receiver

13

Head tracking device

14

adapter

15

Frame with projection surface

16

main computer

17, 17a, 17b, 17c, 17d

render client

18

Motion Control

19, 19a, 19b, 19c, 19d

filter

20

Audio system

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• EP 0836169 A1 [0004]
• DE 69025535 T2 [0006]

Claims (5)

Training and training simulator for industrial truck drivers, characterized in that it comprises a) a computer-aided frame drive mechanism that can be moved in three dimensions ( 2 ) with 6-axis motion system, b) an operator computer ( 9 ) and a main computer ( 16 ) with five rendering clients ( 17 . 17a . 17b . 17c . 17d )) for realistic representation of various realistic scenarios, such as loading and unloading operations, storage systems with tipping and high-bay warehouses, traffic management, behavior in dangerous situations and representation of industrial trucks and a realistic physical representation of the industrial truck environment inside and outside the cab and for performance measurement and Evaluation of the completed training, c) on the frame platform mechanics ( 2 ) modular to be arranged different cabs / cockpits ( 11 ) and / or original material handling equipment, d) a frame ( 15 ), as the driver's cab / cockpit ( 11 ) enclosing cabin with transparent or white opaque cabin walls and cabin ceiling, including entrance door ( 4 ), as projection surfaces for an environmental representation, e) a computer-controlled projection system with at least five projectors arranged outside or inside the cabin ( 6 . 6a . 6b . 6c . 6d ) and rendering clients ( 17 . 17a . 17b . 17c . 17d ) and filters 19 . 19a . 19b . 19c . 19d ) with projection direction directly or via deflection mirrors ( 1 . 1a . 1b . 1c . 1d ) on the cabin walls and the cabin ceiling, f) a head tracking device ( 13 ) as a vision system for the industrial truck driver, which is connected together with an image generator, g) a transmitter to be attached to the body of the industrial truck ( 8th ) and / or a camera with a focus on the industrial truck driver, the transmitter ( 8th ) or the camera with several receivers is connected to the projection system and communicates with them, h) simulation of movement, acceleration or deceleration of the industrial truck by driving the frame platform mechanism ( 2 ) of the movement system by means of an operator computer ( 9 ) and main computer ( 16 ), wherein the acceleration by tilting backwards of the cab and the delay by tilting forward of the cab and cornering and load changes are simulated by charge change, i) simulation of cornering by continuing the rotation of the vision system with at least two actuators for generating vertical and horizontal movements, wherein the movement system triggers a "thrusting effect" and then imperceptibly returns to the starting position, j) a software for recording environmental views on the projection surfaces of the cabin walls of the frame ( 15 ) over the projectors ( 6 . 6a . 6b . 6c . 6d ) with the render client ( 17 . 17a . 17b . 17c . 17d ) all around and upwards as well as movement, visual and reaction sequences into the simulation system, k) a camera for recording in pursuit perspective, the operator computer ( 9 ) and main computer ( 16 ), an evaluation software for assessing the scenario and a performance evaluation of the industrial truck driver, l) a system with haptic feedback of transport contacts, collisions and road bumps, m) an evaluation station with the operation computer ( 9 ) and at least one monitor ( 3 . 3a . 3b ) as well as n) an audio system for industrial truck driver information is designed and the hardware is programmed with appropriate software so that computer peripherals, modules and components of the training and training simulator are interconnected according to block diagram so that an optimal simulation of the operating state is feasible. Training and training simulator according to claim 1, characterized in that by means of an associated software different realistic training scenarios can be initiated, such as the presentation of loading and unloading of trucks, containers, transport trains, conveyor belts and / or handling modern storage systems such as tipping racks, high-bay warehouses; Dealing with process management systems and traffic management as well as container management; Behavior in dangerous situations, process trainings or the presentation of different types of industrial trucks, such as forklifts, lane vehicles, reach trucks as well as the performance measurement and evaluation of the completed training units of the industrial truck driver, including evaluation system. Training and training simulator according to claims 1 and 2, characterized in that it consists of transportable modules and thus can be set up as required in a portable manner. Training and training simulator according to claims 1 to 3, characterized in that on the frame platform ( 2 ) Both an industrial truck operator's replica and an original truck with sensory coupling to the Operator computer ( 9 ) and main computer ( 16 ) is installable. Training and training simulator according to claims 1 to 4, characterized in that the different industrial truck operator modules and / or the original industrial trucks by means of adapters ( 14 ) on the frame platform mechanics ( 2 ) are lockable.

Images