Dock Leveler Position Sensing via Cable-Extension Transducers
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Solution Overview
Problem
Existing dock leveler systems require manual intervention for precise positioning and operation, which can be inefficient and prone to errors, and lack automated solutions for determining the accurate position of deck and lip components throughout their range of motion.
Innovation Solution
A position sensing system utilizing cable-extension transducers and a controller to continuously detect and determine the position of dock leveler components, enabling automated operation and providing feedback for safe loading conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual observation is used to determine leveler component positions, then device complexity is reduced, but automation capability and operational efficiency deteriorate
Solution Approach 1:
The patent replaces manual observation and mechanical position determination with an optical sensing system. Photoelectric sensors continuously detect the positions of deck and lip components, converting mechanical position information into electrical signals for automated control, thereby eliminating the need for human operators while maintaining system reliability
Solution Approach 2:
The patent introduces photoelectric sensors as intermediary devices between the mechanical components (deck, lip) and the control system. These sensors serve as mediators that continuously transmit position information to the controller, enabling automated decision-making without requiring direct human intervention or adding complex mechanical linkages
2Measurement precision
If continuous position sensing is implemented for automated control, then operational precision and safety are improved, but device complexity and cost increase
Solution Approach 1:
The patent employs photoelectric sensors to continuously and precisely detect the positions of deck and lip components throughout their range of motion. This optical measurement system provides accurate real-time position data without mechanical contact, enabling precise automated control while avoiding the complexity of mechanical encoders or potentiometers
Solution Approach 2:
The patent implements continuous position sensing rather than discrete point detection. The photoelectric sensors continuously monitor the positions of deck and lip components throughout their entire range of motion, providing uninterrupted feedback to the controller for smooth automated operation and preventing abrupt movements that could compromise safety
3Ease of operation
If multiple intermediate position detection is added beyond simple limit switches, then operational control precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces traditional mechanical limit switches with photoelectric sensors that can detect multiple intermediate positions. The sensors provide continuous optical feedback about deck and lip positions, enabling the controller to precisely determine when components reach specific intermediate positions without requiring multiple discrete mechanical switches
Solution Approach 2:
The patent uses photoelectric sensors to perform multiple functions simultaneously: detecting limit positions, identifying intermediate positions, determining movement direction, and providing continuous position feedback. This multi-functional sensing approach simplifies the overall control system compared to using separate devices for each function
Data Source
AI summary
An example dock leveler for a loading dock includes a position sensor system that not only senses upper and lower travel limits of the dock leveler's deck and/or lip but can also sense a plurality of intermediate positions between the limits. In some examples, the system includes one or more cable-extension transducers that provide a feedback signal that varies as a function of the deck's position relative to a dock platform and/or varies as a function of the lip's position relative to the deck. Such a position sensor system makes it possible to operate the dock leveler automatically with little to no manual intervention.