Optimizing Precision Material Handling: Elevating Performance and Safety through Enhanced Motion Control in Industrial Forklifts

In adapting to the demands of this modernized landscape, a conventional human-operated forklift within an industrial or warehouse setting falls short. However, the adoption of autonomous forklifts remains a distant prospect for many companies, primarily due to the formidable implementation and switching costs associated with artificial intelligence and complex control mechanisms. To bridge this gap, we present the development of a teleoperated forklift utilizing mecanum wheels for enhanced maneuverability. A key contribution of this work lies in the design of a novel synchronization method for the precise position control of the pallet carriers. This method surpasses the conventional independent and master–slave approaches, demonstrably achieving superior tracking and synchronization performance. Also, a model-based velocity control algorithm was designed for the mecanum wheels to facilitate the mobility of the system. The forklift was successfully able to carry a maximum load of 300 kg. For the comparison of the tracking and synchronization performance, the independent and master–slave methods were also applied to the system. The proposed method showed better performance compared to other structures.