Fork drop prevention system and method of operation thereof

Abstract

The present application relates to a kind of fork anti-falling system and its working method, comprising, hoist frame, it is equipped with several detection devices on it;Several forks, the several forks are arranged on hoist frame, the fork is contacted with detection device, the detection device is used to detect whether the fork is separated from detection device;Receiving device, it is communicated with several detection devices, the receiving device is used to receive the signal sent by several detection devices.The fork anti-falling system and its working method of the present application, by using detection device and receiving device two devices to realize wireless communication, detection device is installed below fork, each fork carries a detection device, when fork is lifted to a certain degree, detection device detects the abnormality of fork immediately through limit switch and sends data to receiving device, then receiving device and control system interact, and stop machine in time, prevent falling damage.

Description

Technical Field

[0001] This invention relates to the field of forklift technology, and in particular to a forklift anti-falling system and its working method. Background Technology

[0002] Forklifts are widely used transport machinery, typically used for the vertical transport of materials, especially in complete sets of processing equipment. They are generally used to solve the material transport problem between process equipment. Forklifts are reliable and widely used.

[0003] Forklifts are a common type of equipment for transferring goods. They are equipped with two forks, shaped like the letter L. The horizontal section of the fork is the working part for placing and lifting goods, while the vertical section is the support part. Through mechanical transmission, heavy goods are transferred up and down, greatly reducing manual labor and minimizing the risk of collisions during transport. They are widely used in warehouses.

[0004] However, the following problems arise during the use of the forklift: the forks are equipped with safety anti-fall devices. The existing solution installs photoelectric sensors at the bottom of the equipment. When the forks fall, the photoelectric sensors are blocked, which prevents timely alarms when the forks fall, causing damage to the forks. Summary of the Invention

[0005] Therefore, the technical problem to be solved by the present invention is to overcome the problem that the existing technology only uses photoelectric sensors, which are only triggered when the forks fall and the photoelectric sensor is blocked, by which time the machine or goods have already been damaged.

[0006] To address the aforementioned technical problems, this invention provides a fork-fall prevention system and its operating method, comprising: a lifting frame with a plurality of detection devices mounted thereon; a plurality of forks disposed on the lifting frame, with each fork corresponding to one of the detection devices, the forks contacting the detection devices, and the detection devices detecting whether the forks have separated from the detection devices; and a receiving device communicating with the detection devices, the receiving device receiving signals emitted by the detection devices. This fork-fall prevention system and its operating method, based on wireless communication technology, overcomes the limitations of some mechanical structures; by employing limit switches and rapid wireless signal interaction, compared to using photoelectric sensors for detection after a fall, it significantly reduces losses caused by fork detachment.

[0007] In one embodiment of the present invention, the detection device includes a detection main control chip, a detection LORA communication module, a DIP switch, a limit switch, and a power detection device.

[0008] In one embodiment of the present invention, the DIP switch is mounted on the hoist frame and is in contact with the forks; the DIP switch is used to modify the coding of the detection device and select the receiving end communication; the battery voltage detection is used to determine the remaining power; the main control chip communicates with the receiving device through the detection LORA communication module.

[0009] In one embodiment of the present invention, the receiving device includes a receiving main control chip, a receiving LoRa communication module, a digital tube, a network port, buttons, and a receiving power detection device.

[0010] In one embodiment of the present invention, the receiving LORA communication module and the detecting LORA communication module communicate with each other; the receiving main control chip communicates with the PLC through the network port; the button is used to modify the address parameters of the receiving device; the digital tube is used to display the alarm detection device; and the receiving power detection obtains the battery voltage to determine the remaining power.

[0011] In one embodiment of the present invention, the detection device is implemented by the following steps:

[0012] S1, Begin;

[0013] S2. Initialize the hardware;

[0014] S3. Check the status of the forks;

[0015] S4, Send data;

[0016] S5, communication and interaction;

[0017] S6. Determine the change in the fork status;

[0018] S7. If the forks do not change, the system will enter sleep mode.

[0019] S8: Fork status changes, organize the data, and return to S4.

[0020] In one embodiment of the present invention, the receiving device is implemented by the following steps:

[0021] S1, Begin;

[0022] S2, Hardware initialization;

[0023] S3, Waiting for data;

[0024] S4. Has data been received?

[0025] S5. If no data is received, return S3.

[0026] S6. Receive data and perform communication processing;

[0027] S7. Are the forks detached?

[0028] S8. The forks fall off, an alarm is sent to the PLC to stop the operation, and then the power consumption is collected and uploaded to the PLC.

[0029] S9. The forks did not fall off. Record the data, then collect the power consumption and upload it to the PLC.

[0030] S10: Collect power consumption data and upload it to the PLC, then return to S3.

[0031] In one embodiment of the present invention, the communication process is as follows:

[0032] S1, Begin;

[0033] S2, Waiting for data to arrive;

[0034] S3, Is there any data entering?

[0035] S4. If data is received, check if the packet header is correct. If the packet header is incorrect, clear the data and return to S2.

[0036] S5. No data entered, return to S2;

[0037] S6. If the packet header is correct, check if the address is correct. If the address is incorrect, clear the data and return to S2.

[0038] S7. The address is correct. Store the data in the array.

[0039] S8. Is there any data being processed?

[0040] S9. Data is being processed; please wait.

[0041] S10: No data is being processed; process the current data.

[0042] S11, Output the output;

[0043] S12. Is there any data waiting to be processed?

[0044] S13. If there is data waiting to be processed, return to S10;

[0045] S14. No data is waiting to be processed. End.

[0046] In one embodiment of the present invention, after the detection device has collected data, if the fork status does not change within 1 minute and the receiving device does not send a refresh request, the detection device enters a sleep mode to save power. If the fork status changes or the receiver sends a refresh request while the detection device is in sleep mode, the detection device immediately wakes up to collect data and completes the interaction with the receiving device.

[0047] In one embodiment of the present invention, the receiving device uses a round-robin algorithm when it is powered on for the first time, that is, it sends data refresh requests and communication interaction intervals to the detection devices one by one according to the device address. When a detection device sends data to the receiving device at the same time, a packet jam may occur. When a packet jam occurs, the detection device will not be able to receive a response. Then, it will stagger the time according to the interaction time sent to each detection device during the previous round-robin to remove the data loss caused by the packet jam.

[0048] The technical solution of the present invention has the following advantages compared with the prior art:

[0049] The fork anti-fall system and its working method described in this invention achieve wireless communication by using two devices: a detection device and a receiving device. The detection device is installed under the fork, and each fork carries a detection device. When the fork is tilted to a certain extent, the detection device immediately detects the abnormality of the fork through a limit switch and sends the data to the receiving device. Then, the receiving device interacts with the Programmable Logic Controller to stop the machine in time and prevent it from falling and being damaged. Attached Figure Description

[0050] To make the content of this invention easier to understand, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings, wherein...

[0051] Figure 1 This is a structural block diagram of the detection device of the present invention;

[0052] Figure 2 This is a flowchart of the detection device of the present invention;

[0053] Figure 3 This is a structural block diagram of the receiving device of the present invention;

[0054] Figure 4 This is a flowchart of the receiving device of the present invention;

[0055] Figure 5 This is a flowchart of the communication process of the present invention. Detailed Implementation

[0056] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, so that those skilled in the art can better understand and implement the present invention. However, the embodiments described are not intended to limit the present invention.

[0057] Reference Figure 1As shown, the fork-fall prevention system and its working method of the present invention include: a lifting frame with a plurality of detection devices mounted thereon; a plurality of forks mounted on the lifting frame, wherein each fork and each detection device is correspondingly arranged, the forks being in contact with the detection devices, and the detection devices being used to detect whether the forks have separated from the detection devices; and a receiving device communicating with the plurality of detection devices, the receiving device being used to receive signals emitted by the plurality of detection devices. This system can detect and stop the machine when the forks are just lifted and before they fall off, reducing damage.

[0058] The detection device includes a main control chip, a LoRa communication module, a DIP switch, a limit switch, and a battery level detector. The DIP switch is mounted on the hoist frame and contacts the forks; it modifies the detection device's encoding and selects the receiving end for communication. The battery level detector uses the battery voltage to determine the remaining battery power. The main control chip communicates with the receiving device via the LoRa communication module. The receiving and detection devices are separate, using wireless interaction for remote data acquisition, solving the problem of inconvenient installation due to mechanical structure limitations. The receiving device uses a network port to interact with the PLC via a protocol, ensuring strong compatibility. The detection device requires a battery; the battery level is determined by an internal AD converter in the microcontroller, which displays the battery level on the control panel. The battery is replaced promptly when the level is low. With the forks properly installed, they press against the limit switches; if the forks are about to fall, the switches will pop up, allowing for rapid acquisition of the fork status.

[0059] The receiving device includes a main control chip, a receiving LoRa communication module, a digital display, a network port, buttons, and a receiving power detector. The receiving LoRa communication module communicates with the detecting LoRa communication module; the main control chip communicates with the PLC via the network port; the buttons are used to modify the receiving device's address parameters, requiring the use of the "+", "-", and "OK" buttons; the digital display shows the alarm detection device; and the receiving power detector measures the battery voltage to determine the remaining power. The device is battery-powered, and with software adjustments, its battery life can reach six months to one year depending on usage, resulting in low cost. The detection device, through limit switches and a communication module, can quickly detect changes in the fork's status, allowing for preventative measures before it falls, thus improving fork safety.

[0060] The implementation of the detection device includes the following steps:

[0061] S1, Begin;

[0062] S2. Initialize the hardware;

[0063] S3. Check the status of the forks;

[0064] S4, Send data;

[0065] S5, communication and interaction;

[0066] S6. Determine the change in the fork status;

[0067] S7. If the forks do not change, the system will enter sleep mode.

[0068] S8: Fork status changes, organize the data, and return to S4.

[0069] The implementation of the receiving device includes the following steps:

[0070] S1, Begin;

[0071] S2, Hardware initialization;

[0072] S3, Waiting for data;

[0073] S4. Has data been received?

[0074] S5. If no data is received, return S3.

[0075] S6. Receive data and perform communication processing;

[0076] S7. Are the forks detached?

[0077] S8. The forks fall off, an alarm is sent to the PLC to stop the operation, and then the power consumption is collected and uploaded to the PLC.

[0078] S9. The forks did not fall off. Record the data, then collect the power consumption and upload it to the PLC.

[0079] S10: Collect power consumption data and upload it to the PLC, then return to S3.

[0080] The communication process is as follows:

[0081] S1, Begin;

[0082] S2, Waiting for data to arrive;

[0083] S3, Is there any data entering?

[0084] S4. If data is received, check if the packet header is correct. If the packet header is incorrect, clear the data and return to S2.

[0085] S5. No data entered, return to S2;

[0086] S6. If the packet header is correct, check if the address is correct. If the address is incorrect, clear the data and return to S2.

[0087] S7. The address is correct. Store the data in the array.

[0088] S8. Is there any data being processed?

[0089] S9. Data is being processed; please wait.

[0090] S10: No data is being processed; process the current data.

[0091] S11, Output the output;

[0092] S12. Is there any data waiting to be processed?

[0093] S13. If there is data waiting to be processed, return to S10;

[0094] S14. No data is waiting to be processed. End.

[0095] After collecting data, if the fork status does not change within 1 minute and the receiving device does not send a refresh request, the detection device will enter sleep mode to save power. If the fork status changes or the receiver sends a refresh request while the detection device is in sleep mode, the detection device will immediately wake up to collect data and complete the interaction with the receiving device.

[0096] The detection device's switch is merely a sensor; the main body is a controller with a sleep mode. During sleep mode, it can be woken up by the receiver to inform it of the current data status, or it can be woken up by pressing and releasing the switch to immediately feed back the changed status to the receiver. The detection device determines the battery's remaining power by acquiring and converting data using an internal ADC. The detection equipment uses a DIP switch to set the address number and select the receiver, distinguishing its own receiver number from other receivers to avoid interference during data exchange.

[0097] When the receiving device is powered on for the first time, it uses a round-robin algorithm, which sends data refresh requests and communication interaction intervals to the detection devices one by one according to the device address. When multiple detection devices send data to the receiving device at the same time, a packet jam may occur. When a packet jam occurs, the detection device will not receive a response. Then, it will stagger the time according to the interaction time sent to each detection device during the previous round-robin to eliminate the data loss caused by the packet jam.

[0098] The receiving device sets its own identifier at the software level via buttons and a digital display for the detection device to select. During the interaction between the two devices, if a data collision occurs, the software will delay the interaction for different durations depending on the address of the detection device before sending data to avoid the collision and ensure stable and accurate communication.

[0099] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. A forklift anti-fall system, characterized in that: include, The hoist frame is equipped with several detection devices. A plurality of forks are provided on the hoist frame, and the plurality of forks are provided in a one-to-one correspondence with a plurality of detection devices. The forks are in contact with the detection devices, and the detection devices are used to detect whether the forks are separated from the detection devices. A receiving device that communicates with several detection devices, the receiving device being used to receive signals emitted by the several detection devices; The detection device includes a main control chip, a LoRa communication module, a DIP switch, a limit switch, and a power detection device. The DIP switch is mounted on the hoist frame and is in contact with the forks; The DIP switch is used to modify the encoding of the detection device and select the receiving end for communication. The battery voltage is obtained to determine the remaining battery power. The detection main control chip communicates with the receiving device through the detection LORA communication module.

2. The fork fall prevention system according to claim 1, characterized in that: The receiving device includes a receiving main control chip, a receiving LoRa communication module, a digital tube, a network port, buttons, and a receiving power detection device.

3. The fork fall prevention system according to claim 2, characterized in that: The receiving LORA communication module and the detecting LORA communication module communicate with each other. The receiving main control chip communicates with the PLC via a network port; The button is used to modify the address parameters of the receiving device; The digital tube is used to display the alarm detection device; The battery voltage is obtained by receiving power detection data to determine the remaining power.

4. The working method of the fork fall prevention system according to claim 3, characterized in that: The implementation of the detection device includes the following steps: S1, Begin; S2. Initialize the hardware; S3. Check the status of the forks; S4, Send data; S5, communication and interaction; S6. Determine the change in the fork status; S7. If the forks do not change, the system will enter sleep mode. S8: Fork status changes, organize the data, and return to S4.

5. The working method of the fork fall prevention system according to claim 4, characterized in that: The implementation of the receiving device includes the following steps: S1, Begin; S2, Hardware initialization; S3, Waiting for data; S4. Has data been received? S5. If no data is received, return S3. S6. Receive data and perform communication processing; S7. Are the forks detached? S8. The forks fall off, an alarm is sent to the PLC to stop the operation, and then the power consumption is collected and uploaded to the PLC. S9. The forks did not fall off. Record the data, then collect the power consumption and upload it to the PLC. S10: Collect power consumption data and upload it to the PLC, then return to S3.

6. The working method of the fork fall prevention system according to claim 5, characterized in that: The communication process is as follows: S1, Begin; S2, Waiting for data to arrive; S3, Is there any data entering? S4. If data is received, check if the packet header is correct. If the packet header is incorrect, clear the data and return to S2. S5. No data entered, return to S2; S6. If the packet header is correct, check if the address is correct. If the address is incorrect, clear the data and return to S2. S7. The address is correct. Store the data in the array. S8. Is there any data being processed? S9. Data is being processed; please wait. S10: No data is being processed; process the current data. S11, Output the output; S12. Is there any data waiting to be processed? S13. If there is data waiting to be processed, return to S10; S14. No data is waiting to be processed. End.

7. The working method of the fork fall prevention system according to claim 6, characterized in that: After collecting data, if the fork status does not change within 1 minute and the receiving device does not send a refresh request, the detection device will enter a sleep mode to save power. If the fork status changes or the receiver sends a refresh request while the detection device is in sleep mode, the detection device will immediately wake up to collect data and complete the interaction with the receiving device.

8. The working method of the fork fall prevention system according to claim 7, characterized in that: When the receiving device is powered on for the first time, it uses a round-robin algorithm, which sends data refresh requests and communication interaction intervals to the detection devices one by one according to the device address. When multiple detection devices send data to the receiving device at the same time, a packet jam may occur. When a packet jam occurs, the detection device will not receive a response. Then, it will stagger the time according to the interaction time sent to each detection device during the previous round-robin to eliminate the data loss caused by the packet jam.

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