Fork-Mounted Load Position Verification System
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Solution Overview
Problem
Existing load detection systems for material handling vehicles can only sense a load in a single position, which is inadequate for accurately determining the position of loads with unique shapes, as they lack multi-position sensing capabilities.
Innovation Solution
A load position verification system comprising a pair of arms extending parallel to the forks of a material handling vehicle, equipped with sensors that transmit and receive beams to indicate the presence or absence of a load, allowing for detection of multiple load positions by interrupting and blocking these beams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single position switch sensor is used to detect load position, then the device complexity is reduced, but the measurement precision of load position is insufficient for unique shaped loads
Solution Approach 1:
The patent divides the load detection function into multiple segments by using multiple sensors positioned at different locations on the forks. Each sensor detects a specific position or aspect of the load, and the controller integrates these segmented detections to determine the overall load position and shape characteristics, thereby achieving precise detection without requiring a single complex sensor
Solution Approach 2:
The patent transitions from single-position detection to multi-dimensional position detection by arranging sensors along the length of the forks and using multiple sensing planes. This dimensional expansion allows the system to detect not only whether a load is present but also its specific position, shape, and orientation by analyzing which sensors are activated
2Measurement precision
If multiple sensors are used to detect multiple load positions, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
The patent designs the sensor system with multi-functionality where the same type of sensor (optical, electromagnetic, or capacitive) performs multiple functions: detecting load presence, determining load position, and inferring load shape characteristics. This universal approach reduces device complexity compared to using different specialized sensors for each function
Solution Approach 2:
The controller acts as an intermediary that processes signals from multiple sensors and synthesizes the load position information. Rather than requiring complex sensor arrangements, the intermediary controller integrates simple sensor inputs to achieve precise multi-position detection through signal processing and pattern recognition
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 accurate detection and verification of load positions on material handling vehicles, improving the precision of load placement and handling by using multiple sensing ranges, which is particularly beneficial for loads with unique shapes.
Implementation Method 1
one or more sensors, each sensor having a transmitter configured to transmit a beam and a receiver configured to receive the beam
Implementation Method 2
the first signal is generated via interruption of a beam extending between a first transmitter and a first receiver of the first sensor
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A load position verification system (125) for detecting a load on a pair of forks (110) of a material handling vehicle (100). The system (125) includes a first arm (405) extending parallel with a first fork (110) of the material handling vehicle (100) and a second arm (410), opposite the first arm (405), extending parallel with a second fork (110) of the material handling vehicle (100). In one example, the system (125) includes one or more sensors (530), each sensor having a transmitter configured to transmit a beam and a receiver configured to receive the beam, positioned within the arms (405; 410). In one example, the system (125) may indicate that no load is on the forks (110) when the receiver receives the beam from the transmitter. In another example, the system (125) may indicate that a load is on the forks (110) when the receiver does not receive the beam from the transmitter.