Forklift Load Capacity Control via Bending Moment Sensor
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Solution Overview
Problem
Existing load capacity control devices for industrial trucks are inefficient due to the need for multiple sensors and are prone to inaccuracies, especially under dynamic conditions, which can lead to tipping instability.
Innovation Solution
A load capacity control device using a bending moment sensor system and a data processing unit that evaluates sensor data to maintain an equal bending moment characteristic curve, refined with load weight information, to check compliance with the load capacity, and includes a teach-in function to determine vehicle-specific curves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple sensors are used to monitor load capacity, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple sensor functions into a single bending moment sensor that simultaneously monitors both the bending moment and, through integration with a load weight sensor, the load weight. This merging approach achieves accurate load capacity monitoring while reducing the overall number of sensors required, thereby resolving the contradiction between measurement precision and device complexity
Solution Approach 2:
The bending moment sensor is designed to serve multiple functions: it monitors the bending moment directly and, in combination with the load weight sensor, enables comprehensive load capacity assessment. This multi-functionality allows the sensor system to achieve high measurement precision without requiring numerous specialized sensors, thus reducing device complexity
2Device complexity
If hydraulic pressure is used to determine load status, then device complexity is reduced, but measurement precision deteriorates due to friction and hysteresis
Solution Approach 1:
The patent replaces the hydraulic pressure-based measurement system with a direct mechanical sensing approach using bending moment sensors and load weight sensors. This substitution eliminates the friction and hysteresis inherent in hydraulic systems, significantly improving measurement precision while maintaining acceptable device complexity through the use of modern sensor technology
3Ease of manufacture
If load capacity data is displayed on a rigid framework plate, then ease of manufacture is improved, but adaptability deteriorates as users cannot query specific load capacities
Solution Approach 1:
The patent transforms the static, rigid framework load capacity plate into a dynamic, interactive display system. The load capacity data is now presented as a family of curves that can be dynamically queried and evaluated by the data processing device, allowing users to obtain specific load capacity information for their required load center of gravity and lifting height, thereby significantly improving adaptability while maintaining ease of manufacture through standardized chart designs
4Ease of operation
If load status is displayed directly without coordinate transformation, then ease of operation is improved, but measurement precision deteriorates under dynamic conditions
Solution Approach 1:
The patent implements a feedback mechanism where the data processing device continuously monitors the bending moment sensor data, compares it with the load capacity curves, and provides real-time feedback on load capacity compliance. This feedback approach maintains ease of operation through clear visual indicators while improving measurement precision under dynamic conditions by continuously adjusting the assessment based on actual sensor readings and coordinate transformations
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
This solution allows for accurate load capacity checking with reduced sensory effort, enhancing the quality of load capacity control and preventing tipping instability by providing real-time warnings and control interventions.
Implementation Method 1
at least one bending moment sensor (22) designed to detect a bending moment in an upper area of the lifting frame (10)
Implementation Method 2
The bending moment sensor system comprises at least one strain measuring sensor, which is arranged in the upper area, in particular in the upper third, of the lifting frame (10)
Data Source
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AI summary
The invention relates to a forklift truck with a lifting mast and a load-handling device arranged vertically on the lifting mast, and a load-bearing capacity control device for monitoring the load-bearing capacity of the forklift truck. It is proposed that the load-bearing capacity control device comprises at least a bending moment sensor configured to detect a bending moment in an upper region of the lifting mast, and a data processing device operatively connected to the bending moment sensor, which is configured to evaluate the sensor data from the bending moment sensor and to monitor compliance with the load-bearing capacity of the forklift truck by maintaining a constant bending moment characteristic (BC) with equal bending moments.