Adaptive loading dock system

Abstract

The present invention relates to an adaptive system for loading docks (1), which allows versatile use both in lorries and in lighter vehicles that do not have pneumatic suspension, such as vans or lightweight lorries, without requiring additional modifications to the suspension. The invention is based on an adjustable system with a pivotable flap (4) or lip that facilitates loading and unloading using an automatic setting for adapting the loading dock to the weight of the vehicle by detecting the angle of inclination of the flap (4) or lip with respect to the loading dock (1), thereby optimising the synchronised movement of the dock (1) with the loading platform of the vehicle.

Description

[0001] DESCRIPTION

[0002] ADAPTIVE LOADING SPRING SYSTEM

[0003] Technology sector

[0004] The present invention belongs to the field of loading dock technology, whether they are ramps or platforms, and more specifically to loading docks adapted for other types of vehicles other than cargo trucks, which have sensors, actuators and / or activators that facilitate the adaptation of the loading dock.

[0005] State of the art

[0006] Currently, loading docks with claw or lip docks usually include automatic levelers that can use hydraulic, mechanical, or pneumatic systems to automatically adjust their height, facilitating the loading and unloading process of trucks and other heavy vehicles with air suspension. However, we do not find loading docks that have an adaptive system to the loading platform of the vehicle that does not have air suspension, such as light trucks or vans of different sizes.

[0007] In this regard, Publication No. US5440772 describes a control system that is activated by the vehicle's proximity to the dock. This system uses sensors to detect the vehicle's position and a set of supports that stabilize the dock leveler based on the detected vehicle position. This system allows the leveler to remain in a safe position if the lip or claw is extended and in contact with the vehicle, thus improving stability during loading and / or unloading operations. However, this system does not automatically adjust the dock leveler to a precise lip or claw tilt range, as it depends directly and solely on the vehicle's proximity.

[0008] US Patent No. 4727613 describes a dock leveler that includes a pivoting bridge plate and a movable extension that facilitates the automatic return of the dock leveler to a neutral position when no vehicle loading platform is present at the loading dock. This system comprises a switch and a sensing element that allows the dock leveler to return to a rest position in a controlled manner. However, while it provides a safety measure in the absence of a vehicle, it does not offer any solution for dynamically adjusting the dock leveler based on the degree of inclination of the lip or claw relative to the loading dock.

[0009] Furthermore, document EP3313761 describes a safety device for use on a dock leveler. The device comprises a platform pivotally connected to a ramp, at least one electronically controlled valve to stop the platform's movement in response to a control signal, and at least one electronic sensor that detects the platform falling. This allows the platform to be stopped safely in the event of any malfunction. Therefore, this device focuses on detecting the platform falling.

[0010] Object of the invention

[0011] With the aim of solving the technical problems mentioned above, as well as providing additional advantages that may be derived later, the present invention relates to an adaptive loading dock system comprising at least,

[0012] - a dock height leveling system,

[0013] - a claw fixed in a hinged manner onto the loading dock by means of a pivot axis,

[0014] - a set of sensors and a set of actuator elements;

[0015] - a control unit, operationally connected to the dock height leveling system and the sensor assembly;where the sensor assembly comprises at least one upper sensor and one lower sensor located at the end of the loading dock nearest to the pivot axis of the fork, where the actuator assembly is fixed to the pivot axis of the fork, and where the actuator assembly comprises at least one upper actuator and one lower actuator configured to activate the upper sensor and the lower sensor respectively when the angle between the fork and the dock falls outside an operational tilt range between the fork and the dock, and where the control unit is configured to activate the leveling system and modulate the height of the dock upon receiving an activation signal from at least one of the sensors, until the tilt angle of the fork with respect to the dock falls within the operational tilt range between the fork and the dock.

[0016] By featuring an adaptive system for loading docks, it allows for versatile use on both trucks and lighter vehicles without air suspension, such as vans or light trucks, without requiring additional suspension modifications. The invention focuses on an adjustable folding lip or claw system that facilitates the loading and unloading process by automatically adapting the loading dock to the vehicle's weight. This is achieved by detecting the angle of inclination of the lip or claw relative to the loading dock, thus optimizing the dock's movement in synchronization with the loading platform.

[0017] The system proposed in the present invention operates as follows: when the van is positioned, the dock lift rises and the lip opens until it makes contact with the loading platform of a vehicle without air suspension, such as a van or light truck. During operation, the main dock structure is locked while the lip remains free to move, maintaining an operational range of motion relative to the dock, known as the operating tilt range. This range is defined by a set of sensors and actuators that may be located along and around the axis of the lip, on the lip itself, and on the loading dock.The set of sensors and actuators that define the operating range of movement, when the angle between the claw and the spring reaches those limits, the sensors send an activation signal to the control unit that activates the spring leveler and corrects the height of the spring, thus avoiding having to adapt the vehicles to different heights and modify their suspension so that they can support a greater weight due to the support of the claw on the vehicle.

[0018] Preferably, the upper sensor sends an activation signal to the control system when it detects a tilt angle between the nail and the spring that exceeds the operating tilt range. The control unit then activates the spring height leveling system, raising the spring height until the tilt angle between the nail and the spring falls within the operating tilt range. Similarly, the lower sensor preferably sends an activation signal to the control system when it detects a tilt angle between the nail and the spring that falls below the operating tilt range. The control unit then activates the spring height leveling system, lowering the spring height until the tilt angle between the nail and the spring falls within the operating tilt range.This allows the operating tilt range of the fork to be defined in real time and the dock height to be adjusted to maintain that range. If the dock is too low relative to the vehicle, the fork will have too steep an incline or slope, which is unsafe for loading and unloading operations.

[0019] Preferably, the operating tilt range between the nail and the spring is a slope of between -3% and 3%.

[0020] With a slope ranging from -3% to 3%, potholes or sudden changes in level are avoided. Thus, the dock and the loading ramp form a working surface for continuous loading and unloading operations, within limits that allow for smooth and unobstructed movement, which greatly increases the safety and speed of these operations.

[0021] Preferably, the upper actuating element and the lower actuating element comprise respective cam-shaped extensions.

[0022] By having a cam-shaped extension, with the simple rotation of the pivot axis of the claw to which both actuators are attached, each actuator can make contact with its respective sensor naturally, thus optimizing the design and structure of the sensor and actuator assembly, resulting in a simple yet highly reliable system.

[0023] The operating tilt range is designed for the distribution of a set of sensors and a set of actuators, subdivided into a subset of at least one upper sensor and actuator, and a subset of at least one lower sensor and actuator. This design allows the distribution of the upper and lower subsets to establish an operating tilt range for the claw or lip. Above this range, upon receiving the respective activation signals, the control unit activates the spring leveler to correct the claw back to an operating tilt range.

[0024] The sensor and actuator assemblies and subassemblies are distributed around the pivot axis of the claw or lip. This allows for gradual adjustment of the claw according to changes in vehicle height during loading and / or unloading operations. Alternatively, the sensor and actuator assemblies and subassemblies can incorporate wireless technology. With wireless technology, such as inductive or optical sensors, the tilt angle between the spring and the claw can be measured without having to position the actuators directly on the pivot axis. Such a sensor and actuator assembly eliminates wear due to friction and reduces the number of components that could cause jams.These types of sensors and actuators have high precision and speed and comprise several subtypes under the same operating protocol, such as travel or positioning sensors, which can determine specific positions or measure displacements of the claw with respect to the loading dock.

[0025] The solution proposed in the present invention can be particularly useful for vehicles without air suspension, especially vans, as it prevents these vehicles from having to support the weight of the spring, which in some cases can reach one ton. This ensures efficient loading without the need for any adaptations or modifications to the vehicle.

[0026] The loading dock of the present invention comprises at least one manual operating mode and one automatic operating mode.

[0027] Preferably, the control unit is physically connected to the dock height leveling system and the sensor array. A physical connection provides stability and reliability, as it is less susceptible to external interference, and offers higher speed.

[0028] Alternatively, the control unit is operationally connected to the dock height leveling system and the sensor array remotely. This remote operational connection, such as that offered by capacitive actuator sensors, enables distributed management, allowing systems to be operated, monitored, or diagnosed from any location. Furthermore, its use reduces wear and tear costs.

[0029] Description of the figures

[0030] Figure 1 shows a profile view of a loading dock according to a preferred embodiment of the present invention with the lip or claw folded down in its non-operational tilt range. Figure 2 shows a profile view of the loading dock of Figure 1 with the lip or claw extended in its operational tilt range.

[0031] Figure 3 shows a perspective and detailed view of the assembly of sensors and actuator elements of a preferred embodiment of the present invention.

[0032] Figure 4 shows a cross-sectional and detailed view of an embodiment of the present invention in which actuating elements are located around the axis of rotation of the nail or lip.

[0033] Detailed description of the invention

[0034] In Figure 1, a preferred embodiment of the present invention can be seen comprising a loading dock height leveling system (2) with a folding claw (4) fixed on a pivot axis (5) with respect to the loading dock (1), two sensors (6.1, 6.2) located at the end of the loading dock (1) closest to the pivot axis (5) of the claw (4), an upper actuator element (7.1) and a lower actuator element (7.2) fixed to the pivot axis (5) of the claw (4), configured to pivot with the movement of said axis (5), and a control unit (3) operatively connected to the two sensors (6.1, 6.2) and to the leveling system (2).

[0035] The control unit (3) has a pre-set operating tilt range between the claw (4) and the spring (1). This range is also defined by the distribution of the sensor and actuator assembly (6, 7) around the rotation axis (5) through their relative positioning. The maximum operating tilt range is limited by at least one upper sensor (6.1) and one upper cam (7.1), and the minimum by at least one lower sensor (6.2) and one lower cam (7.2). This ensures that the rotation of the claw (4) around its axis (5) remains within the operating tilt range, thus providing controlled freedom of movement.When the previously established operating tilt range is reached or exceeded, the control unit (3) activates the loading dock height leveling system (2), thereby modifying the tilt between the claw (4) and the dock (1), restoring it to a relative angle between the dock (1) and the claw (4) within the previously established operating tilt range.

[0036] The loading dock (1) comprises at least two modes of operation, a normal operating mode and an automatic height regulation mode, which is the subject of the present invention.

[0037] In normal operating mode, the user operates the leveling system (2) by means of control, such as a joystick, to raise the height of the dock (1) until it is at the height of the loading area of ​​a vehicle, such as a van.

[0038] After this, the operator would lift the fork (4), either manually or by means of the control means, until it rests on the loading area of ​​the vehicle, after which the automatic height adjustment mode would be activated, either by the user or automatically.

[0039] In automatic height adjustment mode, when the sensors (6) are activated by the actuators (7), the sensors (6) emit an activation signal that is received by the control unit (3). Upon receiving this signal, the control system activates the dock height leveling system (2). Thus, upon receiving the signal, the control unit (3), depending on whether the sensor (6) is upper (6.1) or lower (6.2), will adjust the height of the dock (1) until the angle between the claw (4) and the dock (1) returns to the previously established operating tilt range.

[0040] In a working operation with the adaptive loading dock system (1), the movement of the claw (4) is free, with the control unit (3) receiving a signal from the sensors (6), both upper (6.1) and lower (6.2), which define the tilt range of the claw (4). The positions of the claw (4) or lip around the axis (5) of rotation comprise, at least, a folded position in which the claw is completely folded into a rest position (as can be seen in Figure 1) and locked in its movement, and an extended position (as seen in Figure 2), in which the claw is extended and within its operational tilt range.

[0041] Preferably, the operating tilt range between the claw (4) and the spring (1) may comprise different angle ranges expressed as a percentage of the claw's (4) slope relative to the loading spring (1), such as, for example, a range from -12% to 12% tilt of the claw (4); or more preferably, a range from -5% to 5%; or more preferably, a range from -3% to 3%. The sensor assembly (6) and the actuator assembly (7) may comprise, at least, sets of sensors and actuators of the inductive, microswitch, capacitive, and / or optical type.

[0042] In one possible embodiment, the configuration of the sensor assembly (6) and the actuator assembly (7) comprises inductive sensor-actuators, which prevent mechanical wear and offer high precision and speed. These inductive sensors can be either displacement or positioning sensors, which determine specific positions or measure displacements of the claw (4) relative to the spring (1). This type of sensor facilitates continuous, remote measurement of the operating tilt angle, thus promoting the preservation, through wear prevention, of the mechanism responsible for sending the signal to the control unit (3) to regulate the height of the leveling system (2) of the spring (1), should the tilt between the claw (4) and the spring (1) reach the upper and lower thresholds of the aforementioned operating tilt range.

[0043] In a work operation, whether loading and / or unloading, the present invention comprises a control unit (3) which, when the fork (4) with respect to the dock (1) reaches a slope equal to or above 8%, receives a signal from the lower sensor (6.2), activated by the lower actuator element (7.2), and the control unit (3) activates the dock leveling system (2) to lower the height of the loading dock (1) until the slope of the fork (4) (in freedom of movement) with respect to the dock (1) is between -3% and 3%.

[0044] The sensor assembly (6) and the actuator assembly (7) operate as follows. The upper actuator (7.1) activates the upper sensor (6.1), and the lower actuator (7.2) activates the lower sensor (6.2). The lower actuator (7.2) and the upper actuator (7.1) are located on the pivot axis (5) of the claw (4) and in a predetermined position to define an operating tilt range between the claw (4) and the spring, where the claw is free to move.

[0045] The sensors (6.1, 6.2) of the loading dock (1) detect changes in vehicle height through the slope between the lug (4) and the dock (1) and adjust the leveling system (2) to maintain the dock (1) in an operational position. In Figure 3, it can be seen that the assembly of actuating elements (7), specifically the upper actuating element (7.1) and the lower actuating element (7.2), are cams comprising a circular section that covers the circumference of the shaft to which they are fixed, and an extension configured to contact the respective sensor, determined in their position to delimit an operational tilt range of the lug (4) with respect to the dock (1).

[0046] Additionally, the invention may include a system for controlling the position of the claw around a pivot axis, comprising three main configurations: a rest position, in which the claw is fully folded and locked; an operating position, in which it is fully extended and locked; and a floating or free-moving position. In this last position, the claw is unlocked and can move within a predetermined range of motion between its maximum (operating position) and minimum (rest position) limits.

[0047] In another additional configuration option, the present invention may comprise an adaptive position of the claw (4) with respect to the loading spring (1), wherein the claw (1) retains a freedom of movement comprising from the folded position to above the extended position.

Claims

CLAIMS 1.- Adaptive loading dock system (1) comprising at least, - a dock height leveling system (2) (1), - a claw (4) fixed in a hinged manner on the loading dock (1) by means of a pivot axis (5), - a set of sensors (6) and a set of actuator elements (7); - a control unit (3), operatively connected to the dock height leveling system (2) (1) and to the sensor assembly (6); characterized in that the sensor assembly (6) comprises at least one upper sensor (6.1) and a lower sensor (6.2) located at the end of the loading dock (1) closest to the pivot axis (5) of the claw (4), wherein the actuator assembly (7) is fixed to the pivot axis (5) of the claw (4) and wherein the actuator assembly (7) comprises at least an upper actuator element (7.1) and a lower actuator element (7.2) configured to activate respectively the upper sensor (6.1) and the lower sensor (6.2) when the angle between the claw (4) and the spring (1) falls outside an operating tilt range between the claw (4) and the spring (1), and where the control unit (3) is configured to activate the leveling system (2) and modulate the height of the spring (1) upon receiving an activation signal from at least one of the sensors (6.1, 6.2) until the tilt angle of the claw (4) with respect to the spring (1) falls within the operating tilt range between the claw (4) and the spring (1).

2. Loading dock system (1) according to claim 1, wherein the upper sensor (6.1) sends the activation signal to the control system (3) upon detecting an angle of inclination between the claw (4) and the dock (1) greater than the operating inclination range between the claw (4) and the dock (1), such that the control unit (3) activates the dock height leveling system (2) by raising the height of the dock (1) until the angle of inclination between the claw (4) and the dock (1) is within the operating inclination range between the claw (4) and the dock (1), and wherein the lower sensor (6.2) sends the activation signal to the control system (3) when it detects an angle of inclination between the claw (4) and the spring (1) lower than the operating inclination range between the claw (4) and the spring (1), so that the control unit (3) activates the spring (1) height leveling system (2) by lowering the height of the spring (1) until the angle of inclination between the claw (4) and the spring (1) is within the operating inclination range between the claw (4) and the spring (1). 3.- Adaptive loading dock system (1) according to any one of the preceding claims, wherein the operating tilt range between the claw (4) and the dock (1) is a slope of between -3% and 3%. 4.- Adaptive loading dock system (1) according to any one of the preceding claims, wherein the upper actuating element (7.1) and the lower actuating element (7.2) comprise respective cam-shaped extensions. 5.- Adaptive loading dock system (1) according to any one of the preceding claims, wherein the sensor assembly (6) are inductive sensors. 6.- Adaptive loading dock system (1) according to any one of claims 1 to 4, wherein the sensor assembly (6) consists of optical sensors. 7.- Adaptive loading dock system (1) according to any one of the preceding claims, wherein the control unit (3) is operatively connected to the dock height leveling system (2) (1) and to the sensor assembly (6) in a physical manner. 8.- Adaptive loading dock system (1) according to any one of claims 1 to 6, wherein the control unit (3) is operatively connected to the dock height leveling system (2) (1) and to the sensor assembly (6) in a telematic manner.

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