Abstract: A processor on an industrial vehicle is programmed to identify a metric that characterizes an event associated with an operator of the industrial vehicle, where the metric has a performance parameter to evaluate against the event, and a behavior modification action that defines a desired operator behavior in response to the event. The processor is further operatively programmed to monitor for the event, and record event data that characterizes a response of the vehicle operator to the event. In response to detecting an event, the processor evaluates the recorded event data against the performance parameter to determine whether the vehicle operator demonstrated appropriate behavior for the event, computes a vehicle operator score based upon the evaluation, and performs the behavior modification action where the operator has not been inculcated to respond to the event.

Abstract: A spacer assembly and method for using same to fix a first component to a second component are provided. The method includes positioning the first and second spacer segments between the first and second components, the first and second spacer segments each including an inner face, an opposite outer face, and an exterior surface extending along a longitudinal axis between the inner face and the outer face. The exterior surfaces of the first and second spacer segments are coaxially aligned and secured by a securing device such that the inner faces of the first and second spacer segments define supplementary non-perpendicular angles relative to the longitudinal axis and the outer faces of the first and second spacer segments are parallel to one another. The securing device and the first and second spacer segments are removed after the first component is mechanically coupled to the second component.

Abstract: A materials handling vehicle includes a camera, odometry module, processor, and drive mechanism. The camera captures images of an identifier for a racking system aisle and a rack leg portion in the aisle. The processor uses the identifier to generate information indicative of an initial rack leg position and rack leg spacing in the aisle, generate an initial vehicle position using the initial rack leg position, generate a vehicle odometry-based position using odometry data and the initial vehicle position, detect a subsequent rack leg using a captured image, correlate the detected subsequent rack leg with an expected vehicle position using rack leg spacing, generate an odometry error signal based on a difference between the positions, and update the vehicle odometry-based position using the odometry error signal and/or generated mast sway compensation to use for end of aisle protection and/or in/out of aisle localization.

Abstract: A goods-to-man warehousing system comprises a multilevel racking system, a plurality of mobile storage units, a storage unit transporter, a pick-place vehicle, a mobile storage unit transfer node, and a warehouse management computing hub. The multilevel racking system comprises a vertically and horizontally distributed array of storage bays. One or more of the mobile storage units are positioned in respective ones of the storage bays of the multilevel racking system. The pick-place vehicle comprises pick-place hardware that enables the pick-place vehicle to transfer mobile storage units between a plurality of different, vertically displaced storage bays of the multilevel racking system and the mobile storage unit transfer node of the goods-to-man warehousing system. The storage unit transporter comprises storage unit engagement hardware that enables the storage unit transporter to transport mobile storage units to or from the mobile storage unit transfer node of the goods-to-man warehousing system.

Abstract: A plurality of control elements extend from the base portion of a control module in a materials handling vehicle. The control elements are located adjacent to one another, wherein at least one of the control elements includes mounting structure that permits the control element to be selectively mounted to the base portion in at least first and second positions. The first position defines a first distance between the control element and an immediately adjacent control element and the second position defines a second distance between the control element and the immediately adjacent control element, the second distance being greater than the first.

Abstract: A materials handling vehicle comprises an operator compartment, a compartment tower, a multi-field scanning tool, and mechanisms that facilitate movement along a travel plane in a warehouse. The tool establishes a scan field, and, within scan field bounds, an occupancy detection field and an obstacle detection field. Tool scanning hardware is configured to generate the scan field from a point of origin that is elevated relative to the operator compartment and to expand the scan field such that it intersects the operator compartment and extends laterally beyond lateral edges of the operator compartment such that the occupancy detection field falls within the operator compartment, the obstacle detection field falls outside of the operator compartment, and the multi-field scanning tool is configured to indicate the presence of an occupant in the occupancy detection field and obstacles in the obstacle detection field.

Abstract: An industrial vehicle is provided comprising a drive mechanism, a steering mechanism, a vehicle controller, a camera, and a navigation module. The camera is communicatively coupled to the navigation module, the vehicle controller is responsive to commands from the navigation module, and the drive mechanism and the steering mechanism are responsive to commands from the vehicle controller. The camera is configured to capture an input image of a warehouse ceiling comprising elongated skylights, isolated ceiling lights, and/or active optical targets. The navigation module is configured to distinguish between the ceiling lights and the skylights and send commands to the vehicle controller for localization, or to navigate the industrial vehicle through the warehouse based upon valid ceiling light identification, valid skylight identification, valid active target identification, or combinations thereof.

Abstract: A materials handling vehicle includes a camera, odometry module, processor, and drive mechanism. The camera captures images of an identifier for a racking system aisle and a rack leg portion in the aisle. The processor uses the identifier to generate information indicative of an initial rack leg position and rack leg spacing in the aisle, generate an initial vehicle position using the initial rack leg position, generate a vehicle odometry-based position using odometry data and the initial vehicle position, detect a subsequent rack leg using a captured image, correlate the detected subsequent rack leg with an expected vehicle position using rack leg spacing, generate an odometry error signal based on a difference between the positions, and update the vehicle odometry-based position using the odometry error signal and/or generated mast sway compensation to use for end of aisle protection and/or in/out of aisle localization.

Abstract: A 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 the 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.

Abstract: A materials handling vehicle including a battery receiving space, and a removable battery assembly, wherein: the battery receiving space includes opposing pairs of battery guide pins, each opposing pair arranged on opposite sides of the battery receiving space, and each opposing pair includes a latching pin and a guiding pin; the removable battery assembly includes a battery locking mechanism; the battery locking mechanism includes spring-loaded locking pins that are spring-biased in extended positions and are movable from the extended positions to respective retracted positions; the latching pin of each opposing pair of battery guide pins includes a recess forming a battery latch that is positioned to receive a leading portion of one of the spring-loaded locking pins in the extended position.

Abstract: An industrial truck including a drive frame, a load frame liftable with respect to the drive frame, a drive frame cover at least partly covering the drive frame, and a load frame cover at least partly covering the load frame. The drive frame cover includes a curved portion overlapping a load frame cover. The curved portion includes a curvature aligned with a curved movement path of the load frame cover with respect to the drive frame cover. A cover system including a first cover provided for at least partly covering a first part of an industrial truck, and a second cover provided for at least partly covering a second part of the industrial truck and movable with respect to the first part. The first cover includes a curved portion overlapping the second cover. The curved portion includes a curvature aligned with a curved movement path of the second cover.

Abstract: A materials handling vehicle including a battery receiving space, and a removable battery assembly, wherein: the removable battery assembly includes a battery body and a battery locking mechanism; the battery locking mechanism includes a spring-loaded battery handle and a spring-loaded locking pin; the battery receiving space includes a battery latch positioned to receive the spring-loaded locking pin; the spring-loaded battery handle includes a planar handle cam surface and the spring-loaded locking pin includes a planar pin cam surface such that the handle cam surface engages the pin cam surface with movement of the battery handle relative to the battery body; the spring-loaded battery handle is spring-biased in a locked position; and the spring-loaded locking pin is spring-biased in an extended position and is movable to a retracted position in response to movement of the battery handle from the locked position to an unlocked position.

Abstract: A pallet truck includes a drive frame on which a drive wheel support is pivotably supported, a load frame, which is liftable with respect to the drive frame in a lifting direction, and a hydraulic lift module, which interconnects the drive frame and the load frame. The hydraulic lift module includes a hydraulic lift cylinder, which includes a cylinder barrel and a piston rod, wherein the cylinder barrel includes a cap end at one end portion of the cylinder barrel and a rod end at the other end portion of the cylinder barrel, wherein the piston rod extends outwards from the cylinder barrel at the rod end of the cylinder barrel and wherein a free end of the piston rod is accommodated in the drive frame. In the lifting direction, the cap end of the cylinder barrel is arranged above the rod end of the cylinder barrel.

Abstract: A vehicle-initiated cadenced operator interaction system introduces an operational concept to a vehicle operator via a machine-initiated interaction. Thereafter, interaction is initiated by the industrial vehicle according to a cadence that provides a gap between interactions so that the operator can demonstrate the behavior associated with the introduced concept. Industrial vehicle data associated with the content of the interaction(s) is analyzed and evaluated against pre-defined operational criteria to determine whether the operator is demonstrating the appropriate skill/behavior associated with the interaction(s). Responsive to the operator's demonstrated ability, the system can modify operation of the vehicle to tune the industrial vehicle to the operator. The system can also extend to the operating environment, by interacting with electronic devices, vehicles, machines, etc., in the operating environment to tune the environment to the operator.

Abstract: A remote control device that is to be worn on the appendage of an operator includes a base portion, a wireless communication system, a control, and an insert member. The wireless communication system includes a wireless transmitter for transmitting wireless commands from the remote control device. The control is communicably coupled to the wireless communication system, wherein actuation of the control causes the wireless transmitter to transmit a wireless command. The insert member is removably attached to the base portion.

Abstract: A materials handling vehicle operating system is provided comprising a tag layout where a plurality of entry/exit tag sets are arranged along a travel path at different ones of the entry/exit thresholds of a restricted navigation zone. Each entry/exit tag set comprises a release tag, a restriction tag, and an indicator tag. The indicator tag is positioned between the restriction tag and the restricted navigation zone. The restriction tag is positioned between the release tag and the indicator tag. The tag reader and the reader module cooperate to compare identified tag data with stored tag data and initiate a remediation operation when an indicator tag is identified in place of a restriction tag. Tag layouts for one-way and two-way travel into and out of a restricted navigation zone are also contemplated.

Abstract: A computer-implemented process receives into memory, information designating a task to be performed on an industrial vehicle. The task has a metric associated therewith. The process also extracts vehicle operational data that is generated on the industrial vehicle in response to the industrial vehicle executing the task. The process further receives into memory, information identifying a set of target scores, each target score of the set of target scores defining a different measure of performance associated with the task. The process yet further computes a task evaluation score for each target score in the set of target scores based upon the corresponding measure of performance associated with the task, and creates an adjusted task evaluation indicative of industrial vehicle performance that takes into account an aggregation of the task evaluation score computed for each target score in the set of target scores.

Abstract: A materials handling vehicle comprising a hitch system, and a drive mechanism. The hitch system comprises a hitch and a hitch controller. The hitch comprises a latch, one or more sensors, an actuator, and a receiving member. The latch is positionable between open and closed positions. The actuator is positionable between retracted, intermediate, and extended positions. The receiving member is configured to lead a cart hook to engage the latch when in the closed position. The one or more sensors are configured to detect a position of the latch and a presence of the cart hook received within the receiving member. The hitch controller is configured to position the actuator in one of the retracted position, the intermediate position, and the extended position, and to position the latch in one of the open position and the closed position in response to signals received from the one or more sensors.

Abstract: A materials handling vehicle comprising a hitch, and a drive mechanism. The hitch comprises a latch and a receiving member. The latch is positionable between open and closed positions. The receiving member comprises a pair of inwardly curved side scoops and a central incline member provided between the pair of inwardly curved side scoops, each inwardly curved side scoop having an upper surface, a lower surface opposite the upper surface, an inner surface, an outer surface opposite the inner surface, a rear surface, and a front surface opposite the rear surface. The rear and upper surfaces of the pair of inwardly curved side scoops define an open rear end of the receiving member, the upper surface being sloped at the open rear end. The central incline member and the upper surface of the pair of inwardly curved side scoops cooperate to lead a cart hook to engage the latch.

Abstract: Systems and methods for a materials handling vehicle to navigate a vehicle transit surface in a warehouse environment including a navigation subsystem configured to cooperate with a traction control unit, a braking system, a steering assembly, and an obstacle detection subsystem to: determine whether the materials handling vehicle is approaching, or has arrived at, a potentially contested intersection; associate with the intersection pre-positioned warehouse object data, a set of road rules, and obstacle data; and navigate the materials handling vehicle through the intersection utilizing warehouse navigation maneuvers in combination with the associated set of road rules, obstacle avoidance maneuvers, or both, the warehouse navigation maneuvers accounting for the associated pre-positioned warehouse object data and the obstacle avoidance maneuvers accounting for the obstacle data derived from the obstacle detection subsystem.