Electromagnet Attachment for Material Handling Vehicle Stability
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Solution Overview
Problem
Material handling vehicles risk being dropped when warehouse trucks turn around pallet racks due to instability on forks, necessitating a secure and reliable attachment mechanism.
Innovation Solution
A material handling vehicle equipped with a vertically movable electromagnet for secure attachment to a magnetic surface, paired with sensors to control power supply and adjustable detection range, and horizontal wheels for stability, ensuring secure fit and automated attachment/detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the material handling vehicle is transported on the forks of the warehouse truck, then the vehicle can be moved to different positions in the warehouse, but the vehicle risks being dropped when the truck turns around pallet racks due to instability
Solution Approach 1:
The patent replaces the purely mechanical friction-based attachment (relying on wheel contact with forks) with an electromagnetic attachment system. The electromagnet generates magnetic force to create a reliable connection between the vehicle and the magnetic surface of the load carrier, eliminating the instability caused by mechanical friction during truck maneuvers.
Solution Approach 2:
The patent changes the attachment mechanism from passive mechanical contact to active electromagnetic force. By controlling the magnetic field strength through power supply to the electromagnet, the system can dynamically adjust the attachment force to maintain stability during movement and release when needed, resolving the contradiction between secure attachment and operational flexibility.
2Reliability
If an electromagnet is used for secure attachment to the load carrier, then the vehicle attachment reliability is improved, but the device complexity increases due to additional components
Solution Approach 1:
The patent merges the electromagnet directly into the vehicle chassis structure, integrating the attachment mechanism with the existing vehicle framework. This integration approach minimizes additional components and simplifies the overall system structure while maintaining high attachment reliability through the electromagnetic connection.
Solution Approach 2:
The system incorporates sensors that automatically detect the presence and position of the load carrier, enabling automated control of the electromagnet power supply. This self-service approach eliminates the need for complex manual control systems, reducing device complexity while ensuring reliable attachment through automated sensor-feedback control.
3Device complexity
If the electromagnet is fixed in position, then the structure is simpler, but the electromagnet cannot follow the magnetic surface movements and may lose contact
Solution Approach 1:
The patent makes the electromagnet movable relative to the vehicle chassis, allowing it to dynamically adjust its position to follow the magnetic surface of the load carrier during vertical movements. This dynamic capability ensures continuous magnetic contact and reliable attachment even when the load carrier moves up or down, while the movable mounting remains relatively simple in structure.
Solution Approach 2:
The system uses sensors to detect the position and movement of the magnetic surface, providing feedback control for the electromagnet's position and power supply. This feedback mechanism ensures the electromagnet maintains optimal contact with the load carrier surface, improving attachment reliability without requiring a complex rigid mounting structure.
4Reliability
If the sensor detection range is large, then the attachment automation is more robust, but the detection precision for exact positioning is reduced
Solution Approach 1:
The patent divides the detection task into multiple stages using multiple sensors positioned at different locations. The first sensor detects the approach of the load carrier at a larger distance for automated activation, while the second sensor provides precise positioning information when the vehicle is close to the load carrier. This segmentation allows both robust automation and precise positioning control.
Solution Approach 2:
The system dynamically adjusts the detection range and sensitivity based on the operational phase. During approach, a larger detection range enables automated activation. During positioning, the system transitions to a more precise detection mode with reduced effective range, optimizing both automation reliability and positioning accuracy at different stages of the attachment process.
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
The solution provides a secure and reliable attachment to load carriers, preventing vehicle drops and enhancing stability during transport, with automated and adjustable attachment mechanisms for varied surfaces.
Implementation Method 1
The vehicle also comprises at least one first electromagnet on the underside of the vehicle, such that when the electromagnet is supplied with electric power it will be able to attach the material handling vehicle to a magnetic surface
Implementation Method 2
The material handling vehicle further comprises a sensor at the underside of the vehicle, which sensor is able to control the supply of electric power to the electromagnet
Data Source
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AI summary
A material handling vehicle (1) comprising, a device (8) for lifting and carrying a load, at least a pair of vertical wheels (6), an underside (13), an upper side (12), an energy source (14), a travel motor (16), wherein the material handling vehicle (1) is arranged such that it is able to travel in under a load, lift and transport the load (50), further the material handling vehicle (1) comprises at least one first electromagnet (21) on the underside (13) of the vehicle (1), such that when the electromagnet (21) is supplied with electric power it will be able to attach the material handling vehicle (1) to a magnetic surface (40), wherein the electromagnet (21) is movably attached in the material handling vehicle (1) such that the electromagnet (21) is able to move in vertical direction in relation to the underside (13) of the vehicle (1), wherein the electromagnet (21) is able to follow the magnetic surface (40) as the surface (40) moves in vertical direction in relation to the underside (13) of the material handling vehicle (13), wherein the electromagnet (21) is able to move to between a first and a second end position (I, II), wherein the first end position (I) is a retracted position and the second position (II) is an extend position in relation to the underside (13) of the vehicle (1), at which second position (II) the distance of the lower most surface (37) of the electromagnet (21) to the underside (13) of the vehicle (1) has a predetermined value (X), wherein the material handling vehicle (1) further comprises a sensor (15) at the underside (13) of the vehicle, which sensor (15) is able to control the supply of electric power to the electromagnet (21) based on a detected distance from the sensor (15) to the surface (40) positioned next to the underside (13), wherein the sensor (15) is arranged to have a detection range (R) that is smaller than then predetermined value (X) of the distance of the lower most surface (37) of the electromagnet (21) to the underside (13) of the vehicle (1).