Fork Positioning Light Guidance Using Accelerometer Sensing
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Solution Overview
Problem
Fork handling machines face challenges in accurately positioning fork arms under loads due to limited visibility and parallax issues, leading to inefficiencies and potential product loss, with existing solutions being cumbersome, poorly protected, and lacking in functionality.
Innovation Solution
A method and device that uses a light beam activated based on acceleration vector measurements to guide the positioning of fork arms, including activation during load uptake, with adjustable height and inclination sensing, and remote programmability, to ensure safe and precise engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a light beam device is installed on the forklift to provide positioning feedback, then the positioning accuracy and safety are improved, but the device complexity and installation difficulty increase
Solution Approach 1:
The device is divided into separate functional modules: a light source module (laser or LED) that projects the light beam, an accelerometer module that measures fork arm orientation, and a control module that processes signals and controls beam activation. This segmentation allows each module to be optimized independently and simplifies installation and maintenance while maintaining high positioning accuracy through coordinated operation of the modules
Solution Approach 2:
The device integrates multiple functions into a single system: the light beam provides visual positioning guidance, the accelerometer measures fork arm orientation and inclination, the control module processes data and activates the beam only during load handling operations. This multi-functionality reduces overall system complexity compared to having separate systems for each function while maintaining high measurement precision
2Loss of information
If the light beam is activated continuously to provide constant positioning feedback, then the positioning information availability is improved, but the energy consumption increases
Solution Approach 1:
The light beam is activated periodically rather than continuously, specifically during load handling operations when the forklift is lifting or moving loads. The control module uses acceleration data to detect when the forklift is in a loading position and activates the beam only during these critical phases. This periodic activation ensures positioning information is available when most needed while dramatically reducing energy consumption compared to continuous operation
Solution Approach 2:
The system uses feedback from accelerometers that continuously monitor fork arm orientation and acceleration vectors to determine when the forklift is in a load handling position. This feedback mechanism triggers light beam activation only when necessary, ensuring positioning information is provided during critical operations while minimizing energy consumption by keeping the beam off during non-critical phases
3Reliability
If the device is made robust and protected against collisions with loads, then the reliability is improved, but the device complexity and protection structure requirements increase
Solution Approach 1:
The device includes a protective housing or casing that surrounds the light source and electronic components, designed to absorb or deflect impacts from loads. This protective structure is integrated into the fork arm assembly, providing collision protection before damage can occur to sensitive components. The housing is designed to be robust yet relatively simple in structure, using materials or geometries that naturally resist impact forces while maintaining ease of installation
4Measurement precision
If the light beam activation is based on complex calculations and analyses of acceleration vectors, then the activation precision is improved, but the computational complexity and processing requirements increase
Solution Approach 1:
The system replaces complex mechanical positioning sensors with electronic accelerometers that measure acceleration vectors along three orthogonal axes. The control module performs calculations on these acceleration vectors to determine fork arm orientation and activate the light beam. This substitution of mechanical sensing with electronic sensing and computational processing simplifies the physical device structure while maintaining high activation precision through mathematical analysis of acceleration data
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
Enhances the safety and efficiency of load handling by providing real-time positioning feedback, reducing product loss and operational complexity, while being adaptable and energy-efficient.
Implementation Method 1
said accelerometer continuously measuring the total acceleration vector acting on the forks
Implementation Method 2
a module emitting a light beam, said light beam projecting a light mark on a load to be handled
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a method and device (1) allowing a driver of a handling machine of the forklift type to position and introduce, in complete safety, the forks (2) of the machine under a load (7) to be handled. A light-beam (9) that projects a luminous mark (8) onto the load (7) to be handled informs the driver of the relative position of the forks (2) with respect to the load (7) to be handled. The light-beam (9) is activated and adjusted depending on the different steps of handling and inclination (22) of the forks (2), which, for their part, are identified solely on the basis of the measurement of the acceleration (26) acting on the forks (2). The device (1), which is installed quickly and protected effectively against collisions, has a high degree of operational autonomy. It improves working conditions and reduces product losses.