Nicholas Bates

I currently work at an R&D and test house in Warwickshire, with my primary role being the testing and approval of electric vehicles and battery systems. Building upon the experience I gained during the embedded systems module, I aimed to create a prototype forklift robot, which could be controlled wirelessly by a separate controller. This area interested me as it exposed me to a combination of electrical design, 3D printing, hands-on practical work and programming, which gave me a great deal of variety when completing the various tasks of the project. Despite difficulties throughout, the project was ultimately successful and I was able to produce a wirelessly controlled forklift demonstrator. The lecturers at the university are extremely knowledgeable in their subject areas and as a result I have gained a wide breadth of underpinning knowledge and understanding that will enable me to develop my career further and continue with my professional progression in my workplace.

Hand Controlled Forklift Robot

Introduction

With prospective applications in both non-hazardous and hazardous environments, the production of a wirelessly controlled forklift has the potential to increase safety and efficiency of tasks.

In extreme environments where tasks can be difficult to perform due to the additional safety measures and PPE requirements, not only are worker's jobs made harder to perform, but they are also put at a greater risk of harm (HSE, 2015). By taking the controls away from the driver's seat of the forklift and allowing the operator to control the forklift wirelessly, the worker can operate the vehicle at a distance and from a safer area, away from the hazardous substance and/or environment.

In non-hazardous environments, by gaining the option to control the forklift from outside of the driver's seat, operators can manoeuvre the forklift from whichever position they deem optimal for their own visibility, eliminating any blind spots and thus making their job easier to perform. As blind spots are a leading cause of forklift accidents, the safety of the operator and pedestrians can also be improved (FLC, 2015).

Aims of the project

The aim of this project was to create a prototype forklift which utilises wireless technology to operate the forklift, forktilt and powertrain of the robot from a distance. To achieve this aim, there were four objectives to be completed:

• Design the circuitry and hardware necessary to create the Hand-Controlled Forklift Robot and Wireless Controller
• Build and assemble the Hand-Controlled Forklift Robot and Wireless Controller
• Write the software for the Hand-Controlled Forklift Robot and Wireless Hand Controller
• Test and validate the Hand-Controlled Forklift Robot and Wireless Hand Controller

Hardware and software implementation

• PIC family microcontrollers are used within the forklift and controller circuits
• Circuits were designed in MultiSim and manufactured using university facilities
• Powered using 12 standard AA batteries
• 3D printing was utilised to enable rapid-prototyping
• Programmed with the C programming language using MPLABX IDE
• Wireless Bluetooth control has been implemented using HC05 Bluetooth modules and UART communication
• Two motors are mounted at the rear to allow for forward and reverse driving directions and additionally turning
• Forklift height is controlled with a servo used to drive a belt.▪Forklift tilt angle is controlled using a separate servo connected to the bar which holds the belt

Conclusion

• The project was successful under difficult circumstances
• Created a functioning prototype forklift robot, with control over forklift tilt, forklift height and the wheel motors via another circuit utilising Bluetooth UART communication making the robot completely wireless from the controller

Further work

• Develop software to utilise the gyroscope sensor hardwired into the controller, allowing for control of the forklift using hand gestures
• Mount the controller within a plastic enclosure and attach to the palm of a glove, allowing the switches to still be operated whilst utilising the gyroscope sensor to control the forklift's drivetrain
• Modify the forklift for the addition of two microswitches to act as end stops for the forklift mechanism

Download Nicholas's project overview poster (PDF) (this pdf document is not fully accessible but the contents within it can be viewed via the content on this page)