Vehicle safety interlock device based on angle sensing and control method thereof

Abstract

The present application relates to a vehicle safety interlocking device based on angle sensing and a control method thereof, which is used for installation on a handle rod, the handle rod being a split structure including a base and a rotating seat, and the base and the rotating seat being rotatably connected through a rotating shaft; the vehicle safety interlocking device includes an inductive gear, a driving gear and an absolute value encoder, the inductive gear is used for installation on the base, the driving gear is used for installation on the rotating seat, the driving gear and the inductive gear are in meshing cooperation, and the absolute value encoder is used for installation on the side of the driving gear and linkage with the handle rod, the handle rod is pressed down to drive the driving gear to rotate around the inductive gear, so as to trigger the absolute value encoder. The safety interlocking device has a clever structure, through the linkage of the electric appliance structure with the handle structure, different signal quantities can be fed back under different handle pressing angles, so that the accuracy of human-computer operation can be improved through the difference of the pressing angle, and the use experience is improved.

Description

Technical Field

[0001] This invention relates to the field of industrial vehicle safety control system technology, and in particular to a safety interlock device for the operating handle of industrial vehicles such as forklifts and stackers, specifically a vehicle safety interlock device based on angle sensing and its control method. Background Technology

[0002] Industrial vehicles generally refer to wheeled vehicles (excluding those that run on rails) with at least three wheels and a power drive unit. They are designed to transport, tow, push, lift, stack, or layer various goods on shelves and are controlled by an operator. Common industrial vehicles include counterbalance forklifts, reach trucks, side-mounted forklifts, straddle forklifts, pallet stackers, and three-way stackers.

[0003] In existing technologies, common sensors used in industrial vehicle handle interlock switches include magnetic proximity switches, micro switches, photoelectric sensors, and gyroscopes. These sensors have several drawbacks in application, specifically: Magnetic proximity switches can only detect metallic targets, and the sensing distance varies slightly between different metals. In industrial vehicle handle applications, if the handle material or surrounding environment is unsuitable, inaccurate detection may occur. Compared to some other sensors, their detection accuracy is not high enough, and they may not meet the need for precise judgment in situations requiring high handle position accuracy. Furthermore, they are susceptible to interference from external magnetic fields, leading to misjudgments and affecting vehicle safety control. Micro switches are mechanical switches, prone to failure due to wear and loosening after prolonged use, requiring regular inspection and replacement, increasing maintenance costs and downtime. Moreover, the response speed of mechanical structures is relatively slow, and in operational scenarios requiring rapid response, they may not be able to provide timely and accurate feedback on the handle status. Photoelectric sensors have high requirements for the detection environment. In environments with many interference factors such as dust, smoke, and strong light, their detection accuracy and reliability will be greatly reduced. Different types of photoelectric sensors have different detection distances, and each has certain limitations. In practical applications, if the operating position of the handle exceeds the effective detection range of the sensor, the downward pressure state of the handle cannot be accurately detected. Gyroscopes are relatively expensive, increasing the overall cost of the vehicle. Moreover, they output data such as angular velocity, requiring complex algorithms for data processing and analysis to determine the downward pressure state of the handle, which places high demands on the control system. Furthermore, if the vehicle is not parked on a flat surface, it will produce false judgments, affecting the accuracy of the judgment and the user experience, which is not conducive to the promotion and application of industrial vehicles using these sensors in the market. Summary of the Invention

[0004] To overcome the shortcomings of the prior art, the first objective of this invention is to provide a vehicle safety interlock device based on angle sensing. This safety interlock device has an ingenious structure; through an electrical structure linked to the handle structure, it can provide different signal quantities at different handle pressing angles. This allows for improved accuracy of human-machine operation and enhanced user experience by varying the pressing angle, facilitating the promotion and application of this angle-sensing vehicle safety interlock device in the field of industrial vehicle control systems. The second objective of this invention is to provide a control method for the angle-sensing vehicle safety interlock device. By applying the aforementioned angle-sensing vehicle safety interlock device, real-time monitoring of handle angle changes is possible, enabling more accurate control of the vehicle's operating status, thereby improving operational safety, reducing accidents caused by improper operation, and enhancing the user experience.

[0005] The aforementioned vehicle safety interlock device based on angle sensing and its control method are technically related and belong to the same inventive concept.

[0006] To achieve the first objective mentioned above, the present invention adopts the following technical solution: a vehicle safety interlock device based on angle sensing, for mounting on a handle lever. The handle lever has a split structure including a base and a rotating seat, the base and the rotating seat being rotatably connected via a rotating shaft. The vehicle safety interlock device includes a sensing gear, a driving gear, and an absolute encoder. The sensing gear is mounted on the base, the driving gear is mounted on the rotating seat, and the driving gear meshes with the sensing gear. The absolute encoder is mounted on the side of the driving gear and is linked to the handle lever. When the handle lever is pressed down, it drives the driving gear to rotate around the sensing gear, thereby triggering the absolute encoder.

[0007] As a preferred embodiment of the present invention, the absolute encoder is an analog potentiometer used to convert the pressing angle of the handle rod into a voltage signal. The rotation angle of the handle rod is 0° to 90°, and the 5V signal uniformly corresponds to the 90° area. The handle rod is in the vertical state as the initial state of 0V, and the voltage corresponding to each 1° pressing angle is 5 / 90 = 0.056V.

[0008] As a preferred embodiment of the present invention, the working area of ​​the handle is a downward pressure of 15° to 75°, corresponding to a voltage range of 0.84V to 4.2V.

[0009] As a preferred embodiment of the present invention, the vehicle safety interlock device further includes a control unit, which is electrically connected to the absolute encoder and determines the pressing angle of the handle lever based on the voltage signal output by the absolute encoder, and then controls the operating state of the industrial vehicle based on the pressing angle.

[0010] As a preferred embodiment of the present invention, the vehicle safety interlock device further includes an alarm device, which is electrically connected to the control unit and is used to issue an alarm signal when the rotation angle of the handle exceeds the safe operating angle range.

[0011] As a preferred embodiment of the present invention, the vehicle safety interlock device further includes a display device, which is electrically connected to the control unit and is used to display the downward pressing angle of the handle lever and the corresponding vehicle speed limit information.

[0012] In a preferred embodiment of the present invention, the sensing gear is integrally formed with the base.

[0013] As a preferred embodiment of the present invention, the upper end of the handle rod has an extension rod, and an operating handle is detachably mounted on the top of the extension rod.

[0014] As a preferred embodiment of the present invention, the absolute encoder is a magnetic encoder, which measures the rotation angle of the handle rod by detecting changes in the magnetic field.

[0015] Compared with existing technologies, the beneficial effects of this invention are as follows: The vehicle safety interlock device based on angle sensing in this invention has a simple and ingenious structure. By adding a sensing gear, a driving gear, and an absolute encoder to the handle lever and linking these components with the handle structure, the absolute encoder provides high-precision angle measurement. The cooperation of the sensing gear and the driving gear allows for real-time monitoring of the handle lever's position and angle changes. This enables the feedback of different signal quantities at different handle depressing angles, thereby improving the accuracy of human-machine operation through varying depressing angles. This results in more precise vehicle control, enhancing operational accuracy and reliability, ensuring safe vehicle operation under operator control, and preventing accidents caused by operational errors or loss of control. The overall structure is simple and easy to maintain, requiring no complex mechanical parts, reducing manufacturing costs, and improving the user experience. This facilitates the promotion and application of the aforementioned angle-sensing-based vehicle safety interlock device in the field of industrial vehicle control systems.

[0016] To achieve the second objective mentioned above, the present invention adopts the following technical solution: a control method for a vehicle safety interlock device based on angle sensing, comprising the following steps: S1. The operator inputs the accelerator signal through the control handle; S2. The control unit receives the accelerator signal from the operating handle and processes the signal accordingly. S3. The absolute encoder is used to detect the angle change of the handle and feed the angle change information back to the control unit. S4. The control unit controls the motor output based on the angle change information of the handle lever.

[0017] Compared with the prior art, the beneficial effects of the present invention are: the control method of the vehicle safety interlock device based on angle sensing in the present invention, by applying the above-mentioned vehicle safety interlock device based on angle sensing, can monitor the angle change of the handle in real time, and can more accurately control the operating status of the vehicle, thereby improving the safety of operation, reducing accidents caused by improper operation, and improving the user experience. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the vehicle safety interlock device based on angle sensing in an embodiment of the present invention; Figure 2 yes Figure 1 Enlarged structural diagram at point A; Figure 3 This is a structural breakdown diagram of the vehicle safety interlock device based on angle sensing in an embodiment of the present invention; Figure 4 This is a schematic diagram of the structural assembly of the vehicle safety interlock device based on angle sensing in an embodiment of the present invention; Figure 5 This is a schematic diagram of the angle adjustment state of the handle lever in the vehicle safety interlock device based on angle sensing in an embodiment of the present invention; Figure 6 This is a schematic diagram of the angle adjustment state of the handle lever in the vehicle safety interlock device based on angle sensing in an embodiment of the present invention; Figure 7 This is an installation diagram of the vehicle safety interlock device based on angle sensing in an embodiment of the present invention; Figure 8 This is a logic control diagram of the control method for the vehicle safety interlock device based on angle sensing in an embodiment of the present invention.

[0019] Reference numerals in the attached diagram: 1. Handle lever; 1-1. Base; 1-2. Rotary seat; 1-3. Rotary shaft; 2. Induction gear; 3. Drive gear; 4. Absolute encoder; 5. Extension rod; 6. Operating handle. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of this invention clearer, the invention is described below with reference to specific embodiments shown in the accompanying drawings. However, it should be understood that these descriptions are merely exemplary and not intended to limit the scope of the invention. Furthermore, descriptions of well-known structures and technologies are omitted in the following description to avoid unnecessarily obscuring the concept of the invention.

[0021] In the description of this invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0022] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0023] Example: Figure 1 and Figure 8 As shown, the vehicle safety interlock device based on angle sensing in this invention, based on the handle structure currently used in industrial vehicles, sends the handle rotation angle to the vehicle controller in the form of an analog signal or a CAN signal to achieve vehicle control. In this embodiment, the vehicle safety interlock device is installed on the handle lever 1, which is a split structure. This split design allows for more precise control and monitoring of the handle rotation angle, enabling precise vehicle operation. Furthermore, the split structure makes installation and maintenance of the handle lever 1 more convenient, as each component can be independently disassembled and replaced. Specifically, the handle lever 1 consists of a base 1-1 and a rotating seat 1-2. The base 1-1 can be fixedly installed on the vehicle body to ensure a secure connection between the base 1-1 and the vehicle body, thereby ensuring the stability of the handle structure during use. The base 1-1 and the rotating seat 1-2 are rotatably connected via a rotating shaft 1-3. This reduces wear and extends the service life of the components; moreover, the rotatable connection allows the handle lever 1 to rotate freely within a certain range, providing greater operational flexibility for the operator. The vehicle safety interlock device in this embodiment mainly consists of an induction gear 2, a drive gear 3, and an absolute encoder 4. The induction gear 2 is mounted on the base 1-1, and the drive gear 3 is mounted on the rotating seat 1-2. The drive gear 3 meshes with the induction gear 2. The absolute encoder 4 is mounted on the side of the drive gear 3 and is linked to the handle lever 1. When the handle lever 1 is pressed down, it drives the drive gear 3 to rotate around the induction gear 2, thereby triggering the absolute encoder 4. The absolute encoder 4 provides high-precision angle measurement, ensuring that the vehicle control system can respond according to the precise position of the handle lever 1. The meshing between the induction gear 2 and the drive gear 3 ensures the reliability of the mechanical linkage, allowing the operation of the handle lever 1 to be stably and accurately transmitted to the encoder 4. When the handle lever 1 is pressed down, the drive gear 3 rotates around the induction gear 2, triggering the absolute encoder 4, providing the operator with intuitive operation feedback and enhancing the intuitiveness and accuracy of the operation.

[0024] In this embodiment, the absolute encoder 4 can be an analog potentiometer used to convert the downward angle of the handle lever 1 into a voltage signal. The rotation angle of the handle lever 1 is 0° to 90°, and the 5V signal uniformly corresponds to a 90° region. The handle lever 1 in the vertical state is the initial state of 0V. Each 1° downward angle corresponds to a voltage of 5 / 90 = 0.056V. According to human-machine operation, the working area of ​​the vehicle handle should be between 15° and 75° of downward pressure. Therefore, when the feedback voltage is 0.84V to 4.2V, this voltage range can be defined as the normal operating state of the vehicle. By accurately converting the downward angle of the handle lever 1 into a voltage signal, the device can more precisely control the vehicle's response, improve the sensitivity and accuracy of operation, and since the voltage signal is an easily processed analog signal, it can be directly read and analyzed by the vehicle's control system, simplifying the signal processing process. The uniform 5V signal corresponding to a 90° region ensures that the voltage change of the handle lever 1 at different angles is linear, facilitating accurate calculation and adjustment by the control system. Defining the vertical state of lever 1 as the initial state of 0V provides the operator with a clear reference point, facilitating understanding and operation. Since the relationship between voltage and angle is fixed (0.056V for every 1° of depressurization), the vehicle control system is easy to calibrate and maintain. This embodiment, through precise angle-to-voltage conversion, allows for better monitoring of lever 1's position, thereby improving vehicle operation safety. This conversion method can also adapt to different operating environments and operator needs, providing more flexible control. This embodiment uses an analog potentiometer as the encoder, which may have a lower cost compared to more complex encoders, contributing to a reduction in the overall system cost.

[0025] To further enhance the driving experience, especially for walk-behind industrial vehicles, where operators often walk at different speeds due to varying heights, those with slower walking speeds typically need to fine-tune the accelerator to slow the vehicle and prevent foot injuries. To address this technical issue, in this embodiment, once the downward angle of the handle lever 1 can be accurately determined using the aforementioned structure, the vehicle speed can be limited based on different handle downward angles, thereby adjusting to a sufficiently safe operating distance. Specifically: the vehicle's full-power speed is set to 3000 r / min. When the handle is pressed down to 75°, the operator is furthest from the vehicle, and no speed limit is imposed, i.e., V = 3000 r / min. When the handle is pressed down to 15°, the operator is closest to the vehicle, and the speed is limited to 2400 r / min, with an adaptive speed range of 600 r / min in between. Let S be the accelerator output and V be the final output of the controller. Without the potentiometer, S = V. After adding an angle coefficient, let the current downward angle be X, then V = 2390 + (X - 14) × 10. This embodiment can dynamically adjust the vehicle speed according to the downward angle of the handle 1, thereby ensuring that the operator can maintain a safe operating speed at different operating distances. This not only improves the safety of operation but also enhances the flexibility and adaptability of the system.

[0026] The vehicle safety interlock device in this embodiment also includes a control unit. This control unit is electrically connected to the absolute encoder 4 and determines the downward angle of the handle lever 1 based on the voltage signal output by the absolute encoder 4. It then controls the operating state of the industrial vehicle based on this downward angle. The control unit can accurately determine the downward angle of the handle lever based on the voltage signal, thereby achieving precise control of the vehicle's operating state. Furthermore, by monitoring the position of the handle lever 1 in real time, the control unit can promptly adjust the vehicle's state when abnormal operation is detected, preventing accidents and improving operational safety. The control unit can also quickly adjust the vehicle's operating parameters, such as speed and power output, based on the downward angle of the handle lever 1, making the vehicle more responsive.

[0027] To further improve vehicle safety during use, the vehicle safety interlock device in this embodiment also includes an alarm device. The alarm device is electrically connected to the control unit and is used to issue an alarm signal when the rotation angle of the handle lever 1 exceeds the safe operating angle range. When the rotation angle of the handle lever 1 exceeds the preset safe operating angle range, the alarm device can issue an alarm signal immediately to remind the operator to pay attention and avoid potentially dangerous operations. Through timely alarms, accidents caused by improper operation can be effectively prevented, and the safety of the entire operation process can be enhanced.

[0028] The vehicle safety interlock device in this embodiment also includes a display device. This display device is electrically connected to the control unit and is used to display the downward angle of the handle lever 1 and the corresponding vehicle speed limit information. The display device can display the downward angle of the handle lever 1 and the vehicle speed limit information in real time, allowing the operator to have a clear understanding of the current operating status.

[0029] In this embodiment, the aforementioned sensing gear 2 and the aforementioned base 1-1 are integrally molded. This integral molding design improves the stability of the entire structure, reduces performance degradation caused by loose connections or wear between components, further ensures the accuracy of the rotation angle of the handle 1, and reduces assembly steps in the manufacturing process, simplifying the production flow and improving production efficiency. The upper end of the handle 1 has an extension rod 5, and an operating handle 6 is detachably mounted on the top of the extension rod 5. The combination of the extension rod 5 and the operating handle 6 provides a more ergonomic operating interface, making the operator more comfortable and reducing fatigue during prolonged operation. The detachable operating handle 6 allows for replacement or adjustment according to different operator habits or specific operational needs, improving operational flexibility. The design of the operating handle 6 may include anti-slip or other safety features to ensure that the operator can firmly grip the handle during operation, reducing the risk of accidents caused by slippage.

[0030] The absolute encoder 4 mentioned above can also be a magnetic encoder, which measures the rotation angle of the handle rod 1 by detecting changes in the magnetic field. The non-contact detection method can effectively reduce mechanical wear and improve the durability and reliability of the overall structure.

[0031] The vehicle safety interlock device based on angle sensing in this embodiment has a simple and ingenious structure. It involves adding a sensing gear 2, a driving gear 3, and an absolute encoder 4 to the handle lever 1, and linking these components with the handle structure. The absolute encoder 4 provides high-precision angle measurement. The cooperation of the sensing gear 2 and the driving gear 4 allows for real-time monitoring of the position and angle changes of the handle lever 1. This enables the feedback of different signal quantities at different handle depressing angles, thereby improving the accuracy of human-machine operation and making vehicle control more precise. This enhances the accuracy and reliability of operation, ensuring the safe operation of the vehicle under operator control and preventing accidents caused by operational errors or loss of control. The overall structure is simple and easy to maintain, requiring no complex mechanical parts, reducing manufacturing costs, and improving the user experience. This facilitates the promotion and application of the aforementioned angle-sensing-based vehicle safety interlock device in the field of industrial vehicle control system technology.

[0032] The control method of the vehicle safety interlock device based on angle sensing in this embodiment includes the following steps: S1, the operator inputs an accelerator signal through the operating handle 6; S2, the control unit receives the accelerator signal from the operating handle 6 and processes it according to the signal; S3, the absolute encoder 4 is used to detect the angle change of the handle lever 1 and feeds back the angle change information to the control unit; S4, the control unit controls the motor output according to the angle change information of the handle lever 1.

[0033] The control method of the vehicle safety interlock device based on angle sensing in this embodiment, by applying the above-mentioned vehicle safety interlock device based on angle sensing, can monitor the angle change of the handle in real time, and can more accurately control the vehicle's operating status, thereby improving operational safety, reducing accidents caused by improper operation, and improving the user experience.

[0034] The vehicles in the above embodiments can be forklifts, stackers, or other similar industrial vehicles.

[0035] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention; therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

[0036] Although this document frequently uses reference numerals from the figures, such as 1. handle lever; 1-1. base; 1-2. rotating seat; 1-3. rotating shaft; 2. sensing gear; 3. driving gear; 4. absolute encoder; 5. extension rod; and 6. operating handle, the possibility of using other terms is not excluded. These terms are used merely for the convenience of describing and explaining the essence of the invention; interpreting them as any additional limitation would contradict the spirit of the invention.

Claims

1. A vehicle safety interlock device based on angle sensing, characterized in that: For mounting on a handle rod (1), the handle rod (1) has an extension rod (5) at its upper end, and an operating handle (6) is detachably mounted on the top of the extension rod (5); the handle rod (1) is a split structure including a base (1-1) and a rotating seat (1-2), and the base (1-1) and the rotating seat (1-2) are rotatably connected by a rotating shaft (1-3); the vehicle safety interlock device includes a sensing gear (2), a drive gear (3), and an absolute encoder (4), the sensing gear (2) is used to mount on the base (1-1), and the drive gear (3) is used to mount on the rotating seat (1-2), so The drive gear (3) meshes with the sensing gear (2). The absolute encoder (4) is installed on the side of the drive gear (3) and linked with the handle rod (1). When the handle rod (1) is pressed down, it drives the drive gear (3) to rotate around the sensing gear (2), thereby triggering the absolute encoder (4). The vehicle safety interlock device also includes a control unit. The control unit is electrically connected to the absolute encoder (4) and determines the pressing angle of the handle rod (1) according to the voltage signal output by the absolute encoder (4). Then, it controls the running state of the industrial vehicle according to the pressing angle.

2. The vehicle safety interlock device based on angle sensing according to claim 1, characterized in that: The absolute encoder (4) is an analog potentiometer used to convert the pressing angle of the handle (1) into a voltage signal. The rotation angle of the handle (1) is 0° to 90°. The 5V signal uniformly corresponds to the 90° area. The handle (1) is in the initial state of 0V when it is vertical. The voltage corresponding to each pressing angle of 1° is 5 / 90 = 0.056V.

3. The vehicle safety interlock device based on angle sensing according to claim 2, characterized in that: The working area of ​​the handle (1) is 15° to 75° downward, corresponding to a voltage range of 0.84V to 4.2V.

4. The vehicle safety interlock device based on angle sensing according to claim 3, characterized in that: The vehicle safety interlock device also includes an alarm device, which is electrically connected to the control unit and is used to issue an alarm signal when the rotation angle of the handle (1) exceeds the safe operating angle range.

5. The vehicle safety interlock device based on angle sensing according to claim 4, characterized in that: The vehicle safety interlock device also includes a display device, which is electrically connected to the control unit and is used to display the downward angle of the handle (1) and the corresponding vehicle speed limit information.

6. The vehicle safety interlock device based on angle sensing according to claim 1, characterized in that: The sensing gear (2) is integrally formed with the base (1-1).

7. The vehicle safety interlock device based on angle sensing according to claim 1, characterized in that: The absolute encoder (4) is a magnetic encoder that measures the rotation angle of the handle rod (1) by detecting changes in the magnetic field.

8. A control method for a vehicle safety interlock device based on angle sensing, comprising the vehicle safety interlock device based on angle sensing as described in any one of claims 1 to 7; characterized in that: Includes the following steps: S1. The operator inputs the accelerator signal through the operating handle (6); S2. The control unit receives the accelerator signal from the operating handle (6) and processes it according to the signal; S3. The absolute encoder (4) is used to detect the angle change of the handle rod (1) and feed the angle change information back to the control unit; S4. The control unit controls the motor output according to the angle change information of the handle rod (1).

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