Coast Control System for Pallet Truck Tiller Arm
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Solution Overview
Problem
Dead-man brake mechanisms in vehicles, such as pallet trucks, often require overriding to allow coasting between loading stations, but existing systems engage the brakes when the operator releases the control handle, hindering efficient movement.
Innovation Solution
A coast control system that inhibits the movement of a tiller arm towards the braking position using a spring-loaded mechanism, allowing the vehicle to coast by overriding the dead-man brake mechanism, enabling the operator to maintain control and limit speed when necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dead-man brake mechanism is used to apply brakes when the operator releases the control handle, then safety is improved, but the ability to coast or move freely between loading stations deteriorates
Solution Approach 1:
The brake mechanism transitions from a static dead-man system to a dynamic system with multiple operational modes. The operator can switch between dead-man brake mode and coast control mode, allowing the system to adapt between safety-critical operations and efficiency-critical operations based on real-time needs
2Productivity
If the dead-man brake mechanism is overridden to allow coasting, then productivity is improved, but control precision deteriorates
Solution Approach 1:
The system provides dynamic control characteristics by offering distinct operational modes. In coast control mode, the tiller arm floats freely for efficient coasting, while in dead-man mode, precise control is maintained through continuous operator input. The operator can switch between modes based on operational context
Solution Approach 2:
The control system is segmented into distinct operational modes (dead-man brake mode and coast control mode), each optimized for specific operational requirements. This segmentation allows the operator to select the appropriate control characteristic for the current task
3Productivity
If the tiller arm is inhibited from moving to the braking position, then coasting efficiency is improved, but the ability to quickly apply brakes deteriorates
Solution Approach 1:
The system dynamically adjusts the brake mechanism's behavior based on the selected mode. In coast control mode, the inhibitor prevents automatic brake engagement to maximize coasting efficiency. When needed, the operator can deactivate coast control and return to dead-man mode, instantly restoring full brake application capability
Solution Approach 2:
The coast control inhibitor acts as an intermediary mechanism that temporarily modifies the brake system's behavior. It allows the tiller arm to float freely during coasting operations while maintaining the underlying brake mechanism's integrity and readiness for immediate activation when coast control is deactivated
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the pallet truck to coast or slowly jog forward, aiding in efficient loading operations by preventing the brakes from engaging when the control handle is released, while allowing controlled movement and speed management.
Implementation Method 1
A spring acts upon the tiller arm when an operator releases a control handle attached to the tiller arm to move the tiller arm to a braking position
Data Source
AI summary
In one embodiment, a coast control system, or dead-man brake inhibitor, is associated with a tiller arm that is used for steering a vehicle. A spring acts upon the tiller arm when an operator releases a control handle attached to the tiller arm to move the tiller arm to a braking position which causes an electronically or mechanically actuated brake to be applied. Before releasing the control handle, the operator may actuate the coast control system to inhibit movement of the tiller arm towards the braking position when the control handle is released. The operator may vertically reposition the tiller arm while the coast control system remains actuated by overcoming the inhibiting force applied by the coast control system when the tiller arm is moved toward the braking position and by overcoming the spring acting on the tiller arm when the tiller arm is moved away from the braking position.