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Bin stacking requires the forklift to align position and orientation within a limited tolerance. More stacking levels, bin types, load shapes, and changing lighting increase the difficulty of recognition and docking.

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Solution overview

The solution uses a 3D camera mounted on the smart forklift to estimate the relative pose of the bin on the forks and the target bin. Position and angle offsets are sent to the forklift controller to guide pickup and stacking. The solution suits bins, pallets, and other precision-docking tasks.

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Verified capabilities

  • Positioning accuracy up to ±5 mm and angle accuracy up to 0.1°.
  • Bin-offset recognition range of ±15°.
  • Per-frame processing time below 100 ms.
  • Support for 1–4 levels and 2 × 2 stacking.
Point-cloud data for upper and lower bin docking

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Installation options

Mount the camera on the lifting mechanism and point it horizontally at the bins on both forks. Keep the camera 35–55 cm from the lower edge of the forks; the lifting mechanism position error should not exceed 1 cm.
Single-camera bin-stacking installation
The M Series, such as the M4 Pro or M4 Mega, is recommended. Select the model based on working distance, field of view, and bin dimensions.

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Communication data

The system communicates with the forklift controller over TCP/IP. The controller requests the bin’s X, Y, and θ; the camera returns the following fields.

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Workflow

Avoid heavy dust and humid environments. Keep the camera bracket rigid and stable, and clean the lens regularly to maintain a clear field of view.
AGV forklift bin-stacking demonstration
Bin-stacking recognition result