AUTONOMOUS

FORKLIFT SAFE BRAKING

SYSTEM

Richard Rizki
Master of
Mechatronics
Engineering
University of
Melbourne

Elbert Angdika

Joshua Elisa

Master of
Mechatronics
Engineering
University of
Melbourne

Master of
Mechatronics
Engineering
University of
Melbourne

Dong Hu
Master of
Mechatronics
Engineering
University of
Melbourne

PROJECT AIMS
AIM 1 To design a safe braking system
AIM 2 To design a model scale forklift
AIM 3 To implement and test the system on the model

AIM 1: Safe Braking System Design

Initial Goal
A deceleration profile that allows the FLV to decelerate:
without hitting the obstacle (necessary)
without toppling (necessary)
without allowing the load slips (necessary)

A simulation platform to simulate the designed profile

Design Process
Modelling the dynamics of the FLV
Stability Analysis
Constraining the back wheel not to be lifted
Obtaining threshold by utilising Lagrange to obtain EOM and
confirmed with ZMP approach
Constraining the load not to slip

Test on different profiles

Designing algorithm of utilising the system

Result
EOM
Maximum allowable deceleration and Implementation
on several profiles
Contribution of altering parameters to the stability
MATLAB scripts and simulation to observe the
modelled motion
Algorithm to be implemented

AIM 2: Design of Forklift Prototype

Desired Features of Prototype

Three wheeled
Moves in a straight line
Real-time reading of acceleration
Fork and Mast to support changing of loads
mass and height

Forklift Design

Bearings:
Fork and Mast

Keeping the
forklift aligned
with the track

Tracks and Bearings

Bearings slide along the aluminium track,
keeping the forklift within the track

Readings of Results
Arduino microcontroller
Connection to a computer through a Bluetooth
module
Photodiode encoder reads the speed of each
wheels

AIM 3:
Implementation/Experimentation of
Deceleration Profile
Aim: Confirming the stability threshold obtained in Aim 1
to maintain the FLVs dynamic balance.

Initial Goals
To confirm the deceleration threshold
No Toppling Threshold
No Slipping Threshold

To implement and test 3 types of deceleration profiles

To implement the safe braking system algorithm

Experimental Method
For each loading condition, test with various voltage
deceleration value
In each test, record the deceleration value, see if the
forklift topples or not, and compare the deceleration
value with the theoritical toppling threshold
Tests are carried out on two main loading condition:
250 g load and 600 g load

Testing: 250 g Load

0.5 V / sampling time

0.3 V / sampling time

Threshold = 5.8

Threshold = 5.8

Testing: 600 g Load

0.2 V / sampling time

0.15 V / sampling time

Threshold = 3.3

Threshold = 3.3

Limitations
Deceleration by reducing voltage input instead of
active braking.
Hence, cannot maintain constant deceleration

Inaccuracy in measurement of instantaneous

deceleration, due to sampling time.
Hence, measurement is expected to have some
inconsistency

Encoder does not measure velocity but number of

revolution -> estimation is not accurate. (?)

Future Expansion
Testing of slipping condition (including different friction
coefficients)
Testing at various fork heights
Application of algorithm for actual autonomous
deceleration

EOM at the Instant of Braking

Deceleration Threshold
Toppling Avoidance Threshold

Load Slipping Avoidance Threshold

Deceleration Profiles
Step Braking
Braking

Linear Braking

Quadratic

Sample Simulation Result

Safe Braking Algorithm