Automated Fork Positioning for Multi-Pallet Handling
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Solution Overview
Problem
Industrial vehicles face inefficiencies in load handling operations due to sequential manual steps requiring additional time and effort, and existing automated systems have limited interaction with human operators, leading to inefficient transitions between automated and manual tasks.
Innovation Solution
A load handling system for industrial vehicles equipped with forks to support multiple pallets, a lifting system, and a traction system, controlled by a vehicle controller that enables automated mode operations such as moving forks between pallets and adjusting pallet positions for efficient handling and separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated load handling operations are implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The automated load handling system is segmented into distinct functional modules: a vehicle controller for high-level decision making, a lift actuator for vertical movement control, and a traction actuator for horizontal movement control. Each module operates independently but coordinates through standardized communication protocols, allowing the system to achieve complex automated functionality while maintaining manageable complexity through modular design.
2Loss of time
If sequential manual steps are used for load handling, then ease of operation is maintained, but loss of time increases
Solution Approach 1:
The system performs preliminary actions by pre-positioning the vehicle and forks under the pallet before initiating the lift sequence. The vehicle controller pre-coordinates the lift and traction actuators to prepare for simultaneous or sequential operation, reducing the total time required for load handling while maintaining operational simplicity through automated sequencing.
Solution Approach 2:
The automated system eliminates idle time between manual operations by continuously coordinating lift and traction actions. The vehicle controller maintains continuous monitoring and adjustment of both actuators throughout the load handling process, ensuring that no time is wasted between steps while the operator simply activates the automated sequence.
3Productivity
If automated mode is activated, then productivity increases, but ease of operation decreases
Solution Approach 1:
The vehicle controller serves as an intermediary between the operator and the complex automated functions. The operator interacts with a simple activation interface, while the vehicle controller automatically manages the coordination of lift and traction actuators, handles safety monitoring, and manages the transition between manual and automated modes, thereby hiding system complexity from the operator.
4Productivity
If multiple actuators are coordinated for automated operation, then productivity is improved, but device complexity increases
Solution Approach 1:
The system merges the control functions of multiple actuators into a single vehicle controller that manages both the lift actuator and traction actuator through unified coordination logic. This consolidation reduces the overall system complexity by eliminating the need for separate control systems while maintaining the productivity benefits of coordinated multi-actuator operation.
Data Source
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AI summary
A load handling system for a vehicle includes a set of forks (165) that concurrently supports two or more pallets (161,162) including a first pallet (161) and a second pallet (162) linearly positioned along a length of the forks (165), and a lifting system to raise and lower the forks. A traction system (270) moves the vehicle in a direction of travel associated with withdrawing the forks from the pallets. Additionally, an actuation device generates an activation signal in response to being actuated by an operator, and a vehicle controller places the vehicle in an automated mode of operation in response to receiving the activation signal. In the automated mode of operation, a front end of the forks (165) moves from the second pallet to the first pallet (161), and the first pallet (161) is raised while the second pallet remains on a transport surface. The first pallet (161) is then spaced apart from the second pallet (162) by a predetermined distance and then lowered to the transport surface.