Load detection method for a materials handling vehicle

Abstract

The present invention relates to a load detection method for a materials handling vehicle. The method comprises: receiving a load on a fork carriage of the materials handling vehicle, the fork carriage comprising a first fork and a second fork laterally separated from the first fork; actuating one or more actuation plates of two or more load detection assemblies mounted to the materials handling vehicle from a first extended position to a second compressed position by the load; and, determining whether the load on the fork carriage is properly aligned based on positions of the actuation plates of the load detection assemblies; wherein the positions of the actuation plates correspond to states of proximity sensors within each of the two or more load detection assemblies; and wherein the states of the proximity sensors comprise an unobstructed state and an obstructed state.

Description

[0001] This application is a continuation of the invention patent application entitled “Pallet Detection Systems and Related Methods” having application number 202010265954.0 and filed on April 7, 2020.

[0002] Cross Reference to Related Applications

[0003] This application is based on and claims priority to U.S. Provisional Patent Application No. 62 / 830,110 entitled “Pallet Detection Systems and Related Methods” and filed on April 5, 2019. BACKGROUND

[0004] Material handling vehicles have been developed for transporting cargo loaded onto a generally standardized transport platform, such as a pallet. The pallet can generally include vertical supports, such as stringers, connected to a support platform. The pallet and loaded cargo can be lifted and transported on the material handling vehicle with forks. SUMMARY

[0005] The present disclosure relates generally to load detection systems, and more particularly to pallet detection assemblies for material handling vehicles.

[0006] In one aspect, the present disclosure provides a pallet detection assembly for a material handling vehicle. The pallet detection assembly includes a body defining a cavity and having a proximity sensor at least partially housed within the cavity. The pallet detection assembly further includes an actuation plate having a tab coupled to the actuation plate and extending in a direction toward the body, and an actuator having a cylinder coupled to the body and a plunger slidably received within the cylinder and coupled to the actuation plate. The actuator is configured to movably couple the actuation plate to the body such that the actuation plate is configured to shift non-pivotally relative to the body.

[0007] In one aspect, the present disclosure provides a pallet detection assembly for a material handling vehicle. The pallet detection assembly includes a body defining a cavity and having a proximity sensor at least partially housed within the cavity. The proximity sensor includes a sensor surface. The pallet detection assembly further includes an actuation plate having a tab coupled to the actuation plate and extending in a direction toward the body, and an actuator having a cylinder coupled to the body and a plunger slidably received within the cylinder and coupled to the actuation plate. The actuation plate is configured to shift non-pivotally relative to the body to transition the proximity sensor between an unblocked state in which the sensor surface is unblocked by the tab and a blocked position in which the sensor surface is at least partially blocked by the tab.

[0008] In one aspect, this disclosure provides a material handling vehicle including a fork carrier having a first fork and a second fork laterally separated from the first fork; a first pallet detection assembly arranged adjacent to a lateral outer edge of the first fork; and a second pallet detection assembly arranged adjacent to a lateral outer edge of the second fork. The first pallet detection assembly further includes: a first body defining a first cavity and having a first proximity sensor at least partially housed within the first cavity; a first actuation plate having a first tab coupled to the first actuation plate and extending in a direction toward the first body; and a first actuator including a first cylinder coupled to the first body and a first plunger slidably received within the first cylinder and coupled to the first actuation plate. The first actuator is configured to movably couple the first actuation plate to the first body such that the first actuation plate is configured to be non-pivotibly displaced relative to the first body. The second tray detection assembly further includes: a second body defining a second cavity and having a second proximity sensor at least partially housed within the second cavity; a second actuation plate including a second tab coupled to the second actuation plate and extending toward the second body; and a second actuator including a second cylinder coupled to the second body and a second plunger slidably received within the second cylinder and coupled to the second actuation plate. The second actuator is configured to movably couple the second actuation plate to the second body such that the second actuation plate is configured to be non-pivotibly displaced relative to the second body. Attached Figure Description

[0009] The invention will be better understood when taken into consideration the following detailed description thereof, and features, aspects and advantages other than those set forth above will also become apparent. This detailed description refers to the following drawings.

[0010] Figure 1 This is a top left front isometric view of the pallet detection assembly according to various aspects of this disclosure.

[0011] Figure 2 yes Figure 1 Left view of the tray detection component.

[0012] Figure 3 yes Figure 1 Front view of the tray detection component.

[0013] Figure 4 yes Figure 1 Front view of the main body of the pallet detection component.

[0014] Figure 5 It was sectioned along line 5-5. Figure 3a cross-sectional view of the tray detection assembly of

[0015] Figure 6 is a front view of the tray detection assembly of Figure 3 a cross-sectional view of the tray detection assembly of

[0016] Figure 7 is a top, front, isometric view of another tray detection assembly in accordance with aspects of the present disclosure.

[0017] Figure 8 is a front view of the tray detection assembly of Figure 7

[0018] Figure 9 is a front view of the body of the tray detection assembly of Figure 7

[0019] Figure 10 is a cross-sectional view of the tray detection assembly of Figure 8

[0020] Figure 11 is a partial top, front, isometric view of a materials handling vehicle including a tray detection assembly in accordance with aspects of the present disclosure.

[0021] Figure 12 is a partial top, front, isometric view of a materials handling vehicle of Figure 11 where a tray is supported on a pair of forks.

[0022] Figure 13 is a schematic view of a materials handling vehicle of Figure 11

[0023] is an example output table for the tray detection assembly of Figure 14 Figure 1 is an example output table for the tray detection assembly of

[0024] Figure 15 Figure 7 is a top, front, isometric view of another tray detection assembly in accordance with aspects of the present disclosure.

[0025] Figure 16 is a top, front, isometric view of another tray detection assembly in accordance with aspects of the present disclosure.

[0026] Figure 17 is a top, front, isometric view of another tray detection assembly in accordance with aspects of the present disclosure.

[0027] Figure 18 is a left view of the tray detection assembly of Figure 17

[0028] Figure 19 ​​​​​​is a top left front isometric view of another tray detection assembly of aspects of the present disclosure.

[0029] Figure 20 is a front view of the tray detection assembly of Figure 19

[0030] Figure 21 is a cross-sectional view of the tray detection assembly of Figure 20 DETAILED DESCRIPTION

[0031] Before any aspects of the present disclosure are explained in detail, it is to be understood that the present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The present disclosure is capable of other constructions and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and not limitation. As used herein, the terms "including," "comprising," or "having" and variations thereof are meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless expressly specified or limited otherwise, the terms "mounted," "connected," "supported," and "coupled" and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, "connected" and "coupled" are not restricted to physical or mechanical connections or couplings.

[0032] The following discussion is presented to enable a person skilled in the art to make and use aspects of the present disclosure. Various modifications to the above-described constructions will be readily apparent to those skilled in the art and the generic principles

[0033] It should also be understood that material transport vehicles are designed in a variety of configurations to perform a variety of tasks. It will be apparent to those skilled in the art that the present disclosure is not limited to any particular material handling vehicle and can also provide a variety of other types of vehicle configurations including, for example, order pickers, swing arm vehicles (SWING-ARM VEHICLES), and any other lift truck vehicles. The various systems and methods disclosed herein are suitable for any driver-controlled, walk-controlled, remote-controlled, and autonomous-controlled material handling vehicles. It should also be understood that material transport vehicles are designed in a variety of configurations to perform a variety of tasks. It will be apparent to those skilled in the art that the present disclosure is not limited to any particular material handling vehicle and can also provide a variety of other types of vehicle configurations including, for example, order pickers, swing arm vehicles (SWING-ARM VEHICLES), and any other lift truck vehicles. The various systems and methods disclosed herein are suitable for any driver-controlled, walk-controlled, remote-controlled, and autonomous-controlled material handling vehicles.​​

[0034] As described above herein, the present disclosure provides one or more tray detection assemblies that can be configured to sense tray loading on a materials handling vehicle (MHV). Generally, the tray detection assemblies can include an actuation plate that is selectively movable relative to a body that houses a proximity sensor. The actuation plate can be configured to move or displace non-pivotally relative to the body. That is, each point along the load detection plate moves uniformly and travels the same amount of distance relative to the body.

[0035] Reference Figures 1-3 A tray detection assembly 100 is shown in accordance with one aspect of the present disclosure. The tray detection assembly 100 can include a body 102, an actuation plate 104, an actuator 106, a first spring assembly 107, and a second spring assembly 108. Generally, the actuator 106 can movably couple the actuation plate 104 to the body 102 such that the actuation plate 104 is non-pivotally displaceable relative to the body 102 against a biasing force of the first spring assembly 107 and the second spring assembly 108.

[0036] With specific reference Figures 3-6 The body 102 can define a cavity 110 within which a proximity sensor 112 can be at least partially housed. The body 102 can include a sensor mounting bracket 132, a top wall 134, a first side wall 138, a second side wall 140, a rear wall 142, and a bottom wall 144. Generally, the top wall 134, the first side wall 138, the second side wall 140, the rear wall 142, and the bottom wall 144 can be coupled to one another or formed as a unitary component to define the cavity 110. The rear wall 142 can define a first opening 146, a second opening 148, a third opening 150, with the second opening 148 being longitudinally arranged between the first opening 146 and the third opening 150. In the illustrated embodiment, a barrel 152 can be arranged substantially concentrically with the third opening 150 and can extend from the rear wall 142 in a direction toward the actuation plate 104.

[0037] The sensor mounting bracket 132 can be longitudinally engaged with the second side wall 140 between the first opening 146 and the second opening 148. The sensor mounting bracket 132 can support the proximity sensor 112 within the cavity 110 formed by the body 102.

[0038] In the illustrated embodiment, the proximity sensor 112 can include a sensor surface 154 disposed at an end thereof. The proximity sensor 112 can output a signal (e.g., a magnetic signal, an inductive signal, an electromagnetic sensor, etc.) from the sensor surface 154, and the proximity sensor 112 can be configured to detect whether the output signal emitted from the sensor surface 154 is blocked or unblocked. It should be appreciated that various types of sensors can be used in place of or in addition to the proximity sensor, including one or more mechanical or electrical switches, such as a snap switch or a pressure switch or a strain gauge, as non-limiting examples.

[0039] In the illustrated embodiment, the actuation plate 104 can include a tab 156 coupled to the actuation plate 104, and the tab 156 extends in a direction toward the body 102. Generally, the tab 156 can be disposed on the actuation plate 104 such that, during non-pivotal displacement of the actuation plate 104 toward the body 102, the tab 156 eventually aligns with and covers the sensor surface 154 of the proximity sensor 112. In the illustrated embodiment, the actuation plate 104 can include an angled portion 157 disposed at an end thereof. The angled portion 157 can extend in a direction toward the body 102. In some embodiments, the angled portion 157 can facilitate non-pivotal displacement of the actuation plate 104 relative to the body 102 if a load is dropped onto the forks of the MHV from above (i.e., not slid along the forks).

[0040] The actuator 106 can include a cylinder 158 and a plunger 160 slidably received within the cylinder 158. The cylinder 158 can be received within and coupled to the second opening 148 of the body 102. The plunger 160 can be coupled to the actuation plate 104. The slidable motion of the plunger 160 controlled by being received within the cylinder 158 can provide a non-pivotal coupling between the actuation plate 104 and the body 102. That is, the actuator 106 can be configured to movably couple the actuation plate 104 to the body 102 such that the actuation plate 104 is configured to displace non-pivotally relative to the body 102. The first spring assembly 107 and the second spring assembly 108 can be configured to provide stability and a biasing force against which an input force can displace the actuation plate 104 non-pivotally in a direction toward the body 102.

[0041] The first spring assembly 107 and the second spring assembly 108 can be arranged on opposite sides of the actuator 105. That is, the first spring assembly 107 can be coupled between the body 102 and the actuation plate 104 on one side of the actuator 106, and the second spring assembly 108 can be coupled between the body 102 and the actuation plate 104 on a longitudinally opposite side of the actuator 106. Each of the first spring assembly 107 and the second spring assembly 108 can include a spring 162 and a shaft 164. Each of the springs 162 can be biased between the body 102 and the actuation plate 104 and can be configured to bias the actuation plate 104 in a direction away from the body 102.

[0042] Generally, each of the shafts 164 is slidably received within and concentrically arranged within the springs 162. The shaft 164 of the first spring assembly 107 can be coupled to the first opening 146 of the body 102. The shaft 164 of the first spring assembly 107 can be slidably received by one of the actuation plate 104 and the first opening 146 to compress the spring 162 of the first spring assembly 107 during non-pivoting displacement of the actuation plate 104 in a direction toward the body 102. The shaft 164 of the second spring assembly 108 can be configured to be slidably received within the barrel 152 of the body 102 to compress the spring 162 of the second spring assembly 108 during non-pivoting displacement of the actuation plate 104 in a direction toward the body 102. In the illustrated embodiment, the shaft 164 of the second spring assembly 108 can extend at least partially toward the barrel 152 but not into it when the actuation plate 104 is in the extended position (see Figure 5 ). In some embodiments, the shaft 164 of the second spring assembly 108 can extend at least partially into and through the barrel 152 when the actuation plate 104 is in the extended position (see Figure 21 ).

[0043] With particular reference to Figure 6 During operation, the pallet detection assembly 100 can be mounted to the MHV in a position to ensure that a pallet supported on the forks of the MHV engages the actuation plate 104 when the pallet is properly in place and fully received on the forks. Prior to the MHV engaging a load, or when a load is not fully received on the forks, the actuation plate 104 can be in the extended position (see Figure 6). As the MHV receives a palletized load, the pallet can engage the actuation plate 104 and provide an input force to the actuation plate 104 that overcomes the biasing force of the first spring assembly 107 and the second spring assembly 108, which causes the actuation plate 104 to non-pivotally displace toward the main body 102. As the actuation plate 104 non-pivotally displaces toward the main body 102, the tab 156 coupled to the actuation plate 104 can displace toward the sensor surface 154 of the proximity sensor 112. Once the tab 156 moves an amount sufficient to at least partially cover the sensor surface 154, the proximity sensor 112 can transition from an unblocked state in which the sensor surface 154 is not blocked by the tab 156 to a blocked position in which the sensor surface 154 is at least partially blocked by the tab 156. In some embodiments, the MHV can have fully received the palletized load on the forks when the proximity sensor 112 transitions to the blocked state.

[0044] Referring to Figures 7-10 , in some embodiments, the pallet detection assembly 100 can include one or more proximity sensors 112. For example, as shown in Figures 7-10 , the proximity sensor 112 can be a first proximity sensor 112, and the pallet detection assembly 100 can include a second proximity sensor 200 having a sensor surface 201. The main body 102 can include a second sensor mounting bracket 202 that engages the second side wall 140 longitudinally between the second opening 148 and the third opening 150. The second sensor mounting bracket 202 can support the second proximity sensor 200 within the cavity 110 formed by the main body 102. Generally, the first proximity sensor 112 and the second proximity sensor 200 can be axially aligned and axially separated from one another.

[0045] With particular reference to Figure 10 , the main body 102 can include a second tab 204 coupled to the actuation plate 104 and extending toward the main body 102. The second tab 204 can extend a different distance from the actuation plate 104 toward the main body 102 than the tab 156. In the illustrated embodiment, the second tab 204 can extend a greater distance toward the main body 102 than the tab 156. In this way, for example, Figures 7-10 , the pallet detection assembly can define two pallet detection states. That is, when the second proximity sensor 200 transitions to a blocked state after the actuation plate 104 is displaced a first distance dl by an input force, the MHV can be supporting a load on the forks, but the load can not yet be fully received on the forks. If the actuation plate 104 is further displaced to a distance d2 at which the first proximity sensor 112 transitions to a blocked state, the MHV can have fully received the load on the forks.

[0046] As described above herein, the pallet detection assembly 100 can be installed on a MHV. Turning to Figures 11-13, the MHV 300 can include one or more pallet detection assemblies 100 coupled to the fork carriage 302. The fork carriage 302 can include a fork backrest 304, a first fork 306 and a second fork 308 each coupled to the fork carriage 302, and a pair of pallet detection assemblies 100. In the illustrated embodiment, the MHV 300 can include one of the pallet detection assemblies 100 coupled to the fork carriage 302 adjacent a lateral outer edge 310 of the first fork 306, and another of the pallet detection assemblies 100 coupled to the fork carriage 302 disposed adjacent a lateral outer edge 312 of the second fork 308.

[0047] In some embodiments, the MHV 300 can include a controller 314 having a memory 316 and a processor 318. The controller 314 can be in communication with the first proximity sensor 112, and in some embodiments, the second proximity sensor 200. In some embodiments, the controller 314 can be in communication with a display 320.

[0048] Generally, the arrangement of two or more pallet detection assemblies 100 on the fork carriage 302 can enable detection of whether a load 315 is received on the first fork 306 and the second fork 308 and whether the load is skewed, for example, Figure 14 Possible outputs of the proximity sensors 112 on two pallet detection assemblies 100 of the MHV 300 are illustrated in a configuration of a pallet detection assembly 100 including one proximity sensor 112. When both proximity sensors 112 are unobstructed, the controller 314 can provide an indication to a display 320, a warehouse management system (WMS) in communication with the controller 314, or another external controller, for example, that a load is not received on the forks. If only one of the pallet detection assemblies 100 is in an obstructed state and the other is in an unobstructed state, the controller can provide an indication that a load is skewed on the forks. If both pallet detection assemblies 100 are in an obstructed state, the controller 314 can provide an indication that a load is fully received on the forks and properly aligned.

[0049] As described above herein, in some embodiments, the pallet detection assembly 100 can include a first proximity sensor 112 and a second proximity sensor 200. Figure 15Possible outputs of the first proximity sensor 112 and the second proximity sensor 200 on both tray detection assemblies 100 of the MHV 300 are shown. That is, the MHV 300 can include a first tray detection assembly and a second tray detection assembly, both of which include a first proximity sensor 112 and a second proximity sensor 200. When all of the proximity sensors are unobstructed, the controller 314 can provide an indication that the load is not received on the forks. When one of the second proximity sensors 200 is in an obstructed state while one of the second proximity sensors 200 is in an unobstructed state (both of the first proximity sensors 112 are unobstructed), the controller 214 can provide an indication that the load is arranged askew on the forks. When both of the second proximity sensors 200 are in an obstructed state and both of the first proximity sensors 112 are in an unobstructed state, the controller 214 can provide an indication that the load is centered on the forks but not fully received. When both of the second proximity sensors 200 are in an obstructed state, one of the first proximity sensors 112 is in an obstructed state while one of the first proximity sensors 112 is in an unobstructed state, the controller can provide an indication that the load is received on the forks but askew. When both of the second proximity sensors 200 and both of the first proximity sensors 112 are in an obstructed state, the controller 314 can provide an indication that the load is fully received on the forks and properly aligned.

[0050] In some embodiments, the tray detection assembly 100 can be designed to include alternative shapes and configurations of the actuation plate 104. For example, Figure 16 One embodiment of the tray detection assembly 100 is shown that includes a spacer plate 400 coupled to an outer surface of the actuation plate 104. The spacer plate 400 can provide a smooth surface against which a tray or load can provide an input force to move the actuation plate 104 non-pivotally relative to the body 102.

[0051] Figures 17-18 One embodiment of the tray detection assembly 100 is shown in which the angled portion 157 extends vertically beyond the first end 402 of the body 102 (e.g., from Figure 17 and Figure 18 the top end of the perspective view of FIG. 4). In this way, the angled portion 157 can further assist in moving the actuation plate 104 non-pivotally relative to the body 102, for example, when a load is placed vertically on the forks of the MHV 300.

[0052] Figures 19-21One embodiment of the tray detection assembly 100 is shown in which the tab 156 is integrated in the actuation plate 104 (e.g., formed integrally as a unitary component). In the illustrated embodiment, the actuation plate 104 can not include an angled portion. In the illustrated embodiment, the tab 156 is formed by a top surface 404 of the actuation plate 104. In the illustrated embodiment, the proximity sensor 112 moves (with Figures 1-6 the cavity 110 to a top 406 of the cavity 110 as compared to the embodiment of FIG. 1). In this manner, for example, the top surface 404 can ultimately be displaced to a position in which it blocks the sensor surface 154 of the proximity sensor 112 as the actuation plate 104 is displaced non-pivotally toward the body 102.

[0053] Although various spatial and directional terms can be used herein, such as top, bottom, lower, mid, lateral, horizontal, vertical, front, back, and / or the like, those having ordinary skill in the art will understand that such terms are merely used with respect to the orientations shown in the drawings. The apparatuses and methods described herein can be reversed, rotated, or otherwise modified to be used in orientations other than those described.

[0054] In this specification, embodiments are described in enabling detail in order that the disclosure can be clearly and precisely understood. It is intended, and will be appreciated, that various combinations or modifications of the embodiments described herein can be made without departing from the invention. For example, it will be appreciated that all preferred features described herein can be applied to all aspects of the invention described herein.

[0055] Thus, although the present invention has been described in connection with specific embodiments and examples, it is not necessarily to be construed that the present invention is limited thereto and various other embodiments, examples, uses, modifications and changes of the invention can be included within the scope of the appended claims. The entire disclosure of each patent and publication cited herein is incorporated by reference, as if each were individually incorporated by reference.

[0056] The features and advantages of the present invention will be set forth in the following claims.

Claims

1. A load detection method for a materials handling vehicle, the method comprising: receiving a load on a fork carriage of the materials handling vehicle, the fork carriage including a first fork and a second fork laterally separated from the first fork; actuating one or more actuation plates of two or more load detection assemblies mounted to the materials handling vehicle from a first extended position to a second compressed position by the load; and, determining whether the load on the fork carriage is properly aligned based on positions of the actuation plates of the load detection assemblies; wherein the positions of the actuation plates correspond to states of proximity sensors within each of the two or more load detection assemblies; and wherein the states of the proximity sensors include an unobstructed state and an obstructed state; wherein the load detection assemblies have a body defining a cavity, and wherein the body includes the proximity sensors housed at least partially within the cavity; wherein the actuation plates include tabs connected to the actuation plates, and wherein the tabs extend from the actuation plates in a direction toward the body; the method further comprising connecting the actuation plates to the body by actuators, wherein the actuators include cylinders connected to the body and plungers slidably received within the cylinders and connected to the actuation plates; and displacing the actuation plates relative to the body by non-pivoting movement of the actuation plates.

2. The method of claim 1, wherein determining whether the load on the fork carriage is properly aligned includes: monitoring the states of the proximity sensors; and determining proper alignment of the load from the states of the proximity sensors; wherein, in the unobstructed state, the proximity sensors are unobstructed by the tabs, and wherein, in the obstructed state, the proximity sensors are at least partially obstructed by the tabs.

3. The method of claim 2, wherein the load detection assembly comprises: a first load detection assembly including a first proximity sensor disposed proximate a laterally outer edge of the first fork; and a second load detection assembly including a second proximity sensor disposed proximate a laterally outer edge of the second fork.

4. The method of claim 3, further comprising: determining that the load is not properly loaded on the fork carriage when both the first proximity sensor and the second proximity sensor are in the unobstructed state.

5. The method of claim 3, further comprising: determining that the load is properly loaded on the fork carriage when both the first proximity sensor and the second proximity sensor are in the obstructed state.

6. The method of claim 3, further comprising: determining that the load is skewed on the fork carriage when one of the first proximity sensor or the second proximity sensor is in the obstructed state and the other of the first proximity sensor or the second proximity sensor is in the unobstructed state.

7. The method of claim 1, further comprising: biasing the actuation plates in a direction away from the body by one or more spring assemblies, wherein the spring assemblies are disposed on opposite sides of the actuators, and wherein each spring assembly is coupled between the body and the actuation plates.

8. A load detection method for a materials handling vehicle, the method comprising: monitoring, by a controller, states of two or more load detection assemblies mounted to the materials handling vehicle; actuating one or more actuation plates of the load detection assemblies mounted to the materials handling vehicle from a first position to a second position by a load; and, determining whether the load is properly aligned based on positions of the actuation plates of the load detection assemblies; wherein each load detection assembly includes a main body defining a cavity and at least one proximity sensor housed at least partially within the cavity; wherein each actuation plate includes at least one tab connected to the actuation plate and extending toward the main body; and wherein in the first position the proximity sensor is unobstructed by the tab, wherein in the second position the proximity sensor is at least partially obstructed by the tab, and wherein a state of the load detection assembly is determined based on a state of the proximity sensor; the method further comprising connecting the actuation plate to the main body via an actuator, wherein the actuator includes a cylinder connected to the main body and a plunger slidably received within the cylinder and connected to the actuation plate; and displacing the actuation plate relative to the main body via non-pivoting movement of the actuation plate.

9. The method of claim 8, further comprising: biasing the actuation plate in a direction away from the main body via one or more spring assemblies, wherein the spring assemblies are disposed on opposite sides of the actuator, and wherein each spring assembly is connected between the main body and the actuation plate.

10. The method of claim 8, wherein the materials handling vehicle includes a fork carriage, and wherein the fork carriage includes a first fork and a second fork laterally separated from the first fork.

11. The method of claim 10, wherein the load detection assembly comprises: a first load detection assembly having a first proximity sensor disposed proximate a laterally outer edge of the first fork; and a second load detection assembly having a second proximity sensor disposed proximate a laterally outer edge of the second fork.

12. The method of claim 11, further comprising: determining that a load is not properly loaded on the fork carriage when both the first proximity sensor and the second proximity sensor are unobstructed.

13. The method of claim 11, further comprising: determining that a load is properly loaded on the fork carriage when both the first proximity sensor and the second proximity sensor are obstructed.

14. The method of claim 11, further comprising: determining that a load is skewed on the fork carriage when one of the first proximity sensor or the second proximity sensor is obstructed and the other of the first proximity sensor or the second proximity sensor is unobstructed.

15. A load detection method for a materials handling vehicle, the method comprising: monitoring, via a controller, a state of one or more proximity sensors held at least partially within a main body of two or more load detection assemblies mounted on the materials handling vehicle; actuating one or more actuation plates of the load detection assemblies mounted on the materials handling vehicle, wherein the actuation plates include one or more tabs connected to the actuation plates and extending toward the main body of the load detection assemblies; displacing the actuation plates relative to the main body via non-pivoting displacement of the actuation plates to transition the proximity sensors between an unobstructed state, in which the proximity sensors are unobstructed by the tabs, and an obstructed state, in which the sensors are at least partially obstructed by the tabs; and, determining whether a load is properly aligned based on the state of the one or more proximity sensors; the method further comprising connecting the actuation plate to the main body via an actuator, wherein the actuator includes a cylinder connected to the main body and a plunger slidably received within the cylinder and connected to the actuation plate.

16. The method of claim 15, further comprising: displacing the actuation plate relative to the body by non-pivoting displacement of the actuation plate to transition the second proximity sensor between an unblocked state in which the second proximity sensor is unblocked by the second tab and a blocked state in which the second proximity sensor is at least partially blocked by the second tab; when both proximity sensors are in the unblocked state, indicating an empty state of the materials handling vehicle; when only one proximity sensor is in the blocked state, indicating a partially loaded state; and when both proximity sensors are in the blocked state, indicating a loaded state; wherein the second proximity sensor is at least partially housed within the body, and wherein the second tab is coupled to the actuation plate and extends toward the body. ​

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