Hydraulic handcart with level and weight detection function

Abstract

The utility model discloses a hydraulic trolley with horizontal and weight detection function, including basic structure and safety monitoring component, the basic structure includes frame assembly, hydraulic lifting system, lifting connecting rod mechanism, manual operation handle switching mechanism, steering wheel and walking wheel, the safety monitoring component includes weight sensor, horizontal inclination sensor, audible -visual annunciator, display, junction box and lithium cell, the utility model solves the defect that original hydraulic trolley has no overload monitoring, no inclination early warning, guarantees the temporary transfer function when AGV failure, significantly improves equipment use security and functionality, and simple structure, the implementation cost is low, and the operation is convenient.

Description

Technical Field

[0001] This utility model relates to the field of safety monitoring technology for warehousing and handling equipment, specifically to a hydraulic handcart with safety monitoring function, which is suitable for scenarios such as shelf transfer and material handling, and can be used as an emergency replacement device when AGV fails. Background Technology

[0002] In modern industrial automated warehouse management systems, AGVs (Automated Guided Vehicles) are core equipment for material handling and rack transport. However, they are prone to unexpected shutdowns due to mechanical wear, electrical faults, and other unforeseen circumstances, severely impacting warehouse continuity. To address this, hydraulic handcarts have been proposed as temporary alternatives. Through a purely mechanical structure and manually driven design, they offer advantages such as low cost, easy maintenance, and high reliability. They can be quickly deployed when the main AGV fails, ensuring uninterrupted warehouse efficiency.

[0003] However, existing hydraulic handcarts still have significant safety and functional defects:

[0004] Without weight monitoring function: It is impossible to detect the weight of the transferred goods in real time, which can easily lead to structural deformation of the handcart due to overloading (such as bent forks and cracked frame), and even cause safety accidents such as falling goods and tipping of shelves, while also shortening the service life of the equipment.

[0005] Lack of levelness monitoring function: When the warehouse floor is uneven, or when turning or going uphill, the handcart is prone to tilting, but there is no effective early warning mechanism. Once the tilt angle is too large, the shelves or goods are prone to slipping, causing damage to materials and risk of personal injury.

[0006] Lack of safety warnings: Even if overloading or tilting occurs, there are no real-time warnings, making it difficult for operators to detect danger in time, which further amplifies safety hazards.

[0007] In existing technologies, while some warehousing equipment uses sensors for safety monitoring, such as the Chinese utility model patent CN217893267U "A Weight Monitoring Device for an Electric Forklift," it is only applicable to electrically driven forklifts, relying on the onboard motor power supply system. It cannot be adapted to the emergency AGV failure scenario of this application, which involves "purely mechanical hydraulic drive without an onboard motor," and it does not integrate horizontal tilt angle monitoring. Another example is the Chinese utility model patent CN216587234U "Anti-tilt Transport Vehicle for Warehouses," which passively achieves anti-tilt through mechanical structures (such as anti-fall baffles), lacking real-time tilt angle detection, weight detection, and audible and visual alarms. Furthermore, it is not adapted to the purely mechanical, manually driven scenario of "temporary replacement for AGV failure." These devices differ significantly from the hydraulic handcart of this application in structure, power form, and usage scenario, making direct compatibility impossible. Therefore, an improved solution is needed that adds safety monitoring functions while retaining the advantages of the original hydraulic handcart to address these issues. Summary of the Invention

[0008] Purpose of the Invention: This utility model addresses the shortcomings of existing hydraulic handcarts, which lack weight monitoring, levelness monitoring, and safety warning functions. It provides a hydraulic handcart with level and weight detection functions, aiming to achieve the following objectives:

[0009] (1) Real-time monitoring of the weight of transferred goods to prevent equipment damage and safety accidents caused by overloading;

[0010] (2) Monitor the horizontal tilt angle of the handcart in real time, warn of the risk of tilting, and prevent goods from slipping and shelves from tipping over;

[0011] (3) The sound and light alarms promptly remind operators, improving safety during use;

[0012] (4) Maintain the core advantages of pure mechanical structure and human-driven operation, without increasing the cost of complex electrical control, and ensure rapid adaptability when AGV fails.

[0013] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0014] A hydraulic handcart with level and weight detection functions includes a basic structure and a safety monitoring component; the basic structure includes a frame assembly, a hydraulic lifting system, a lifting linkage mechanism, a manual operation handle switching mechanism, steering wheels and traveling wheels; the safety monitoring component includes a weight sensor, a level tilt sensor, an audible and visual alarm, a display, a junction box and a lithium battery;

[0015] The frame assembly provides the mounting base and support for all components. Its overall structure is a frame structure adapted for warehousing and handling, including a horizontal cargo platform and two symmetrically arranged forks. The forks are long strip-shaped high-strength steel plate bending parts, which are vertically welded and fixed to the front end of the lower surface of the horizontal cargo platform. The two forks are arranged in parallel and the spacing is adapted to the width of the standard warehouse rack (default 800mm~1200mm), providing installation space for the horizontal tilt sensor.

[0016] The lifting linkage mechanism is installed below the frame assembly and connected to the steering wheel and the travel wheel via pins; the hydraulic lifting system is fixedly connected to the frame assembly at the top and to the lifting linkage mechanism at the bottom to transmit lifting power; the manual operation handle switching mechanism is located in the middle of the hydraulic lifting system, and the power output of the hydraulic lifting system is realized through manual operation; the weight sensor is embedded in the bearing surface of the frame assembly for real-time collection of weight data of goods on the handcart.

[0017] The horizontal tilt sensor is fixed on the vertical reference surface of the frame assembly. The vertical reference surface is an integrated vertical plate between the two forks of the frame assembly. Since the forks are the core component of the frame assembly's cargo-carrying function, the sensor is installed between the two forks. It can directly reflect the overall horizontal state when the forks are carrying cargo, ensuring that the collected tilt angle data is strongly correlated with the stability of the cargo. It is used to collect the horizontal tilt angle data of the handcart in real time.

[0018] The display is mounted on the top of the vehicle frame assembly and is set at a preset angle of 30° for easy observation by the operator;

[0019] The display integrates a control unit, which is electrically connected to a weight sensor, a horizontal tilt sensor, and an audible and visual alarm.

[0020] The control unit presets a weight threshold (default 1500kg) and a horizontal tilt angle threshold (default 2°). It can receive weight data transmitted by the weight sensor and tilt angle data transmitted by the horizontal tilt angle sensor. When the detected data exceeds the corresponding preset threshold, the control unit sends a trigger signal to the audible and visual alarm to drive the audible and visual alarm to work.

[0021] The junction box is used to centrally arrange the connection lines between the weight sensor, horizontal tilt sensor, audible and visual alarm, display and lithium battery, and the interior is reserved for lithium battery installation.

[0022] The lithium battery is a rechargeable lithium battery, installed in the reserved space of the junction box, providing working power for all safety monitoring components, and a charging interface is provided on the side of the junction box.

[0023] The display is equipped with a threshold adjustment module and a data display module; the threshold adjustment module can manually adjust the weight threshold and horizontal tilt angle threshold according to the weight of the shelf and the warehouse floor conditions.

[0024] The data display module can display the current weight of the goods and the horizontal tilt angle of the handcart in real time.

[0025] There are four audible and visual alarms. Two of them are installed in the area corresponding to the forks at the front of the frame assembly, and the other two are installed at the rear of the frame assembly near the operator. Each audible and visual alarm integrates an LED light and a buzzer to emit audible and visual warnings.

[0026] The buzzer volume of the sound and light alarm is ≥85dB, and the LED light is a red high-frequency flashing light (flashing frequency 1.5Hz-2Hz), ensuring that operators can promptly detect the warning signal in a noisy warehouse environment.

[0027] The hydraulic lifting system includes a manual hydraulic pump and a hydraulic telescopic rod; the manual hydraulic pump is linked to a manual operating handle switching mechanism, and the extension and retraction of the hydraulic telescopic rod can be controlled by operating the manual operating handle switching mechanism, thereby driving the lifting linkage mechanism to drive the steering wheel and the traveling wheel to achieve the lifting and lowering of the vehicle frame assembly.

[0028] The weight sensor is a combination of four strain gauge weight sensors with a total range of 4000 kg and a measurement accuracy of ±0.05%. The surface of the weight sensor is covered with a wear-resistant stainless steel layer to prevent wear on the sensor during loading and unloading of goods.

[0029] The horizontal tilt sensor is a dual-axis tilt sensor with a measurement range of ±90° and a measurement accuracy of ≤±0.05°.

[0030] The horizontal tilt sensor is equipped with a waterproof and dustproof outer shell, making it suitable for humid or dusty warehouse environments.

[0031] The steering wheel is a swivel wheel with a diameter of 160mm, and the traveling wheel is a fixed wheel with a diameter of 80mm. The steering wheel and the traveling wheel work together to enable the handcart to turn flexibly and travel smoothly.

[0032] The surface of the steering wheel is covered with a polyurethane wear-resistant layer.

[0033] The manual operating handle switching mechanism includes an operating handle, a fixed shaft, and a switching valve. The fixed shaft is fixedly connected to the hydraulic lifting system. The operating handle can rotate around the fixed shaft. When the operating handle is raised, the switching valve is controlled to switch to the lifting position. When the operating handle is pressed down, the switching valve is controlled to switch to the lowering position. When the operating handle is reset to the neutral position, the switching valve returns to the closed position, thereby realizing the three working states of the hydraulic lifting system: lifting, lowering, and stopping.

[0034] The junction box can be an IP67 waterproof junction box, installed in a concealed location on the side of the frame assembly.

[0035] The lithium battery can be a 12V / 5Ah rechargeable lithium battery with overcharge and over-discharge protection. The junction box has a charging interface on the side, and a single charge can meet more than 8 hours of continuous operation.

[0036] This application powers the safety monitoring components with an independent rechargeable lithium battery, eliminating the need for an external motor and making it perfectly suited for purely mechanical drive scenarios.

[0037] Compared with the prior art, the present invention has the following beneficial effects:

[0038] Safety is significantly improved: weight sensors provide real-time overload protection to prevent equipment structural damage; tilt sensors warn of tilt risks to prevent goods from slipping; and audible and visual alarms provide timely reminders to reduce the probability of safety accidents.

[0039] Functional expansion: While retaining the core function of "temporary replacement for AGV failure", a new safety monitoring function has been added to adapt to more complex workshop scenarios (such as uneven ground and heavy-duty rack transfer);

[0040] Highly practical: The newly added components have a simple structure and controllable cost, without changing the original purely mechanical and manually driven design.

[0041] It is easy to maintain, and operators can get started without additional training. Attached Figure Description

[0042] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments, and the advantages of the present invention in the above and / or other aspects will become clearer.

[0043] Figure 1 It is a perspective diagram of the overall system structure.

[0044] Figure 2 It is an oblique top view.

[0045] Figure 3 It is an oblique bottom view.

[0046] Figure 4 This is a diagram of a shelf trolley in actual use.

[0047] Explanation of reference numerals in the attached drawings: 1-Chassis assembly, 2-Hydraulic lifting system, 3-Lifting linkage mechanism, 4-Manual operation lever switching mechanism, 5-Steering wheel, 6-Weight sensor, 7-Horizontal tilt sensor, 8-Audible and visual alarm, 9-Walking wheel, 10-Display, 11-Junction box, 12-Lithium battery. Detailed Implementation

[0048] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0049] like Figure 1 , Figure 2 , Figure 3 and Figure 4 As shown, the first embodiment of this utility model provides a hydraulic handcart with level and weight detection functions, including a basic structure and a safety monitoring component; the basic structure includes a frame assembly 1, a hydraulic lifting system 2, a lifting linkage mechanism 3, a manual operation handle switching mechanism 4, steering wheels 5, and traveling wheels 9; the safety monitoring component includes a weight sensor 6, a horizontal tilt sensor 7, an audible and visual alarm 8, a display 10, a junction box 11, and a lithium battery 12;

[0050] The frame assembly 1 is constructed from Q345 high-strength steel plate through bending and welding, forming the basic framework of the entire equipment while balancing strength and lightweight design. Its upper part is a 10mm thick horizontal cargo platform (with an anti-slip sandblasted surface). The lower front end is welded with two symmetrical forks: the forks are 1200mm long (adapting to standard warehouse racking depth), 150mm wide, and 200mm high, with rounded fork tips (to prevent scratching the racking). The distance between the two forks is 1000mm, with an 8mm thick vertical plate welded in between (serving as a reinforcing structure for the frame assembly and also as the mounting reference surface for the horizontal tilt sensor 7). The lower rear end has a pre-installed mounting slot for the lifting linkage mechanism 3. The lifting linkage mechanism 3 is connected to both sides of the bottom of the frame assembly 1 via pins. Steering wheels 5 and traveling wheels 9 are installed at the front and rear ends of the lifting linkage mechanism 3, respectively, enabling the equipment to move and steer. The top of the cylinder of the hydraulic lifting system 2 is fixedly connected to the central base of the frame assembly 1, and the end of its push rod is connected to the middle crossbeam of the lifting linkage mechanism 3. The manual operation handle switching mechanism 4 is inserted into the pump core of the hydraulic lifting system 2. By manually reciprocating the lever, hydraulic oil can be driven to raise the push rod, which in turn lifts the frame assembly 1 and the goods on it through the lifting linkage mechanism 3.

[0051] Weight Sensor 6: Four strain gauge gravity sensors with a range of 0–1000 kg are selected. The installation method is as follows: four mounting slots are made between the cargo support crossbeams on the upper surface of the frame assembly 1. One weight sensor 6 is embedded in each mounting slot, ensuring its sensing surface is in full contact with the lower surface of the cargo platform. This distributed installation method can uniformly collect cargo weight signals, improving measurement accuracy. The signal lines from the four sensors are combined and connected to the junction box 11.

[0052] Tilt sensor 7: A Maike dual-axis tilt sensor (model: LVT428T) with a range of ±90° is selected. It is fixed to the vertical plate between the two forks at the front of the frame assembly 1 using a mounting bracket, ensuring its reference plane is parallel to the vehicle body reference plane. This position is close to the vehicle's center of gravity, accurately reflecting the vehicle's tilt state during movement. Its signal line is also connected to junction box 11.

[0053] Display 10 and Controller: Display 10 is an industrial-grade LED digital display screen with waterproof function. It is mounted on the frame assembly 1 near the manual operating handle at a certain angle (30°) via a bracket for easy viewing by the operator. Display 10 integrates a microprocessor control unit (which can be used as a simple controller) to receive and process weight and tilt angle signals, preset alarm thresholds, and drive the audible and visual alarms. It is connected to the junction box 11 via a cable and receives signals from the weight sensor 6 and the horizontal tilt angle sensor 7.

[0054] Audible and visual alarm 8: To achieve the best warning effect, a total of 4 audible and visual alarms are installed. Two are installed in a conspicuous position at the front of the frame assembly 1, and the other two are installed at the rear of the frame near the operator. Each audible and visual alarm 8 integrates a high-brightness red LED and a buzzer greater than 85dB. Its power and control signals are provided by the alarm drive circuit inside the display 10.

[0055] Junction Box 11: A waterproof junction box with an IP67 protection rating, installed in a concealed location on the side of the frame assembly 1. It is used to centrally connect and protect all sensor cables and the main cable leading to the display 10, improving the reliability and cleanliness of the system. It also has space reserved inside for installing a lithium battery, which is convenient for future replacement and charging of the lithium battery. The lithium battery provides power to all components.

[0056] Workflow implementation: After the equipment is powered on, the weight sensor 6 and the horizontal tilt sensor 7 begin to collect data in real time.

[0057] Weight monitoring: The display 10 receives and processes the weight signal, displaying it as the real-time weight (unit: kg). The default weight alarm threshold is 1500 kg. When the real-time weight exceeds this value, the display 10 controls the audible and visual alarm 8 to activate, emitting a continuous beeping sound and flashing a red light to warn the operator that the load has been exceeded.

[0058] Tilt Angle Monitoring: Display 10 simultaneously receives and processes tilt angle signals, displaying them as real-time tilt angles (unit: °). The default tilt angle alarm threshold is 2°. When the device tilts beyond 2° due to uneven ground or improper operation, the audible and visual alarm 8 will also activate.

[0059] Threshold adjustment: Operators can access the settings menu via the buttons on display 10 to customize the alarm thresholds for weight and tilt angle based on the flatness of different warehouse floors and the weight of commonly used shelves, thus enhancing the adaptability of the equipment.

[0060] The advantages of this invention are: while retaining the core advantages of traditional hydraulic handcarts—purely mechanical drive, low cost, easy maintenance, and suitability for warehousing and logistics—and their role as an emergency replacement for AGVs in case of failure, it effectively solves the major safety hazard of traditional handcarts—the lack of early warning during overloading and tilting—by integrating a compact and cost-controllable safety monitoring system. This system is easy to install, does not change the original vehicle structure or operating habits, yet greatly improves the safety, intelligence, and applicability of the equipment.

[0061] The above description is merely a preferred embodiment of this utility model, but the protection scope of this utility model is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the technical scope disclosed in this utility model, based on the technical solution and inventive concept of this utility model, should be included within the protection scope of this utility model.

Claims

1. A hydraulic handcart with level and weight detection functions, characterized in that, It includes a basic structure and safety monitoring components; the basic structure includes a frame assembly (1), a hydraulic lifting system (2), a lifting linkage mechanism (3), a manual operating handle switching mechanism (4), steering wheels (5) and running wheels (9); the safety monitoring components include a weight sensor (6), a horizontal tilt sensor (7), an audible and visual alarm (8), a display (10), a junction box (11) and a lithium battery (12); The frame assembly (1) provides the mounting base and support for all components, including a horizontal cargo platform and two symmetrically arranged forks. The forks are long strip-shaped high-strength steel plate bending parts, which are vertically welded and fixed to the front end of the lower surface of the horizontal cargo platform. The two forks are arranged in parallel and the spacing is adapted to the width of the standard warehouse rack, providing installation space for the horizontal tilt sensor (7). The lifting linkage mechanism (3) is installed below the frame assembly (1) and is connected to the steering wheel (5) and the traveling wheel (9) by a pin. The hydraulic lifting system (2) is fixedly connected to the frame assembly (1) at the top and to the lifting linkage mechanism (3) at the bottom; The manual operation handle switching mechanism (4) is located in the middle of the hydraulic lifting system (2) and the power output of the hydraulic lifting system (2) is realized through manual operation; The weight sensor (6) is embedded in the bearing surface of the frame assembly (1); The horizontal tilt sensor (7) is fixed on the vertical reference surface of the frame assembly (1), which is an integrated vertical plate between the two forks of the frame assembly (1). The display (10) is mounted on top of the frame assembly (1); The display (10) integrates a control unit, which is electrically connected to the weight sensor (6), the horizontal tilt sensor (7), and the audible and visual alarm (8), respectively. The control unit presets a weight threshold and a horizontal tilt threshold, and can receive weight data transmitted by the weight sensor (6) and tilt data transmitted by the horizontal tilt sensor (7). When the detected data exceeds the corresponding preset threshold, the control unit sends a trigger signal to the audible and visual alarm (8) to drive the audible and visual alarm (8) to work.

2. A hydraulic handcart with level and weight detection functions according to claim 1, characterized in that, The junction box (11) is used to centrally arrange the connection lines between the weight sensor (6), the horizontal tilt sensor (7), the audible and visual alarm (8), the display (10) and the lithium battery (12), and the internal space is reserved for the installation of the lithium battery (12). The lithium battery (12) is a rechargeable lithium battery, which is installed in the reserved space of the junction box (11), and the junction box (11) has a charging interface on its side.

3. A hydraulic handcart with level and weight detection functions according to claim 2, characterized in that, The display (10) is equipped with a threshold adjustment module and a data display module; the threshold adjustment module can manually modify the weight threshold and horizontal tilt angle threshold according to the weight of the shelf and the condition of the warehouse floor; The data display module can display the current weight of the goods and the horizontal tilt angle of the handcart in real time.

4. A hydraulic handcart with level and weight detection functions according to claim 3, characterized in that, There are four sound and light alarms (8), two of which are installed in the area corresponding to the forks at the front end of the frame assembly (1), and the other two are installed at the rear of the frame assembly (1) near the operator. Each sound and light alarm (8) integrates an LED light and a buzzer to issue sound and light warnings. The buzzer volume of the sound and light alarm (8) is ≥85dB, and the LED light is a red high-frequency flashing light.

5. A hydraulic handcart with level and weight detection functions according to claim 4, characterized in that, The hydraulic lifting system (2) includes a manual hydraulic pump and a hydraulic telescopic rod; the manual hydraulic pump is linked with the manual operating handle switching mechanism (4), and the extension and retraction of the hydraulic telescopic rod can be controlled by operating the manual operating handle switching mechanism (4), thereby driving the lifting linkage mechanism (3) to drive the steering wheel (5) and the walking wheel (9) to achieve the lifting of the frame assembly (1).

6. A hydraulic handcart with level and weight detection functions according to claim 5, characterized in that, The weight sensor (6) is a combination of four strain gauge weight sensors with a total range of 4000 kg and a measurement accuracy of ±0.05%. The surface of the weight sensor (6) is covered with a wear-resistant stainless steel layer.

7. A hydraulic handcart with level and weight detection functions according to claim 6, characterized in that, The horizontal tilt sensor (7) is a dual-axis tilt sensor with a measurement range of ±90° and a measurement accuracy of ≤±0.05°.

8. A hydraulic handcart with level and weight detection functions according to claim 7, characterized in that, The horizontal tilt sensor (7) is equipped with a waterproof and dustproof outer shell.

9. A hydraulic handcart with level and weight detection functions according to claim 8, characterized in that, The steering wheel (5) is a swivel wheel, and the traveling wheel (9) is a directional wheel; The surface of the steering wheel (5) is covered with a polyurethane wear-resistant layer.

10. A hydraulic handcart with level and weight detection functions according to claim 9, characterized in that, The manual operating handle switching mechanism (4) includes an operating handle, a fixed shaft and a switching valve; the fixed shaft is fixedly connected to the hydraulic lifting system (2), the operating handle can rotate around the fixed shaft, when the operating handle is raised, the switching valve is controlled to switch to the lifting position, when the operating handle is pressed down, the switching valve is controlled to switch to the lowering position, when the operating handle is reset to the middle position, the switching valve returns to the closed position, thereby realizing the three working states of the hydraulic lifting system (2) of lifting, lowering and stopping.

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