Fork Sensor Feedback Control for Pallet Insertion Alignment
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Solution Overview
Problem
Conventional autonomously guided vehicles face challenges in accurately inserting a fork into a pallet when the pallet's position and posture deviate from the set position and posture, and struggle to identify characteristic information in varying workplace environments.
Innovation Solution
A forklift system equipped with a vertically movable fork, a sensor unit comprising contact and non-contact sensors, and a control unit that adjusts the vehicle's movement based on sensor detections to accurately align and insert the fork into the pallet's insertion hole, including navigation and laser sensors for precise positioning and angle control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional autonomously guided vehicles operate under a fixed assumption of pallet position and posture, then the system structure remains simple, but the system fails when pallet position and posture deviate from the set values
Solution Approach 1:
The system dynamically adjusts the fork's position and orientation based on real-time sensor feedback about pallet position and posture. The control unit continuously modifies the forklift's movement commands to accommodate varying pallet configurations, transforming a static system into a dynamic adaptive one.
Solution Approach 2:
The sensor unit provides continuous feedback about pallet position, posture, and insertion hole location to the control unit. This feedback loop enables the system to detect deviations from expected positions and automatically adjust fork positioning to achieve accurate insertion.
2Measurement precision
If the sensor unit uses both contact and non-contact sensors, then detection accuracy is improved, but device complexity increases
Solution Approach 1:
The sensor unit merges contact sensors and non-contact sensors into a single integrated assembly mounted on the fork. This combination allows the system to benefit from both sensor types simultaneously - non-contact sensors for early detection and contact sensors for confirmation - while sharing common mounting structure and control integration.
Solution Approach 2:
The sensor unit serves multiple functions: detecting external objects, determining their position, verifying insertion, and providing feedback for control adjustments. By making the sensor unit multi-functional, the patent reduces the need for separate detection systems while improving overall measurement precision.
3Manufacturing precision
If the forklift system continuously adjusts vehicle body position and fork position based on sensor signals, then docking accuracy is improved, but control complexity increases
Solution Approach 1:
The forklift system performs self-correction by automatically adjusting its own vehicle body position and fork position based on sensor feedback. The control unit processes sensor signals and generates appropriate movement commands without external intervention, enabling the system to self-correct positioning errors in real-time.
Solution Approach 2:
The system replaces manual mechanical positioning with automated sensor-based control. Instead of relying on mechanical alignment methods or operator skill, the patent uses sensor detection and electronic control to achieve precise docking, substituting mechanical complexity with sensorimotor integration.
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 docking accuracy by allowing the fork to be accurately inserted into the center of the pallet's insertion hole, improving safety and productivity by adapting to changes in pallet position and posture, and effectively detecting obstacles to ensure precise alignment.
Implementation Method 1
a non-contact sensor configured to be provided at the sensor body and to emit light to the outside upon detecting an external object
Data Source
AI summary
An exemplary embodiment of the present disclosure provides a forklift system. The system includes a vehicle body of a forklift; a fork configured to be vertically movable at one side of the vehicle body; a sensor unit; and a control unit. The sensor unit is configured to be disposed at a front end portion of the fork to detect an external object. The control unit is configured to control movement of the vehicle body or the position of the fork according to a detection signal generated by the sensor unit.