Forklift Cargo Handling Control for Tilt-Compensated Fork Insertion
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Solution Overview
Problem
Conventional cargo handling control devices for forklift trucks face issues with accurately positioning the fork into the pallet hole, leading to picking up failures due to variations in pallet detection and fork control, causing the fork to be misaligned with the pallet walls.
Innovation Solution
A cargo handling control device for forklift trucks that includes a lift cylinder, tilt cylinder, and sensors to detect the approach distance and position of the fork relative to the pallet, adjusting the fork's movement and tilt to ensure proper insertion into the pallet hole, regardless of pallet tilting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If tilting control and vertical movement control of the fork are performed along the inner wall of the upper wall or lower wall of the pallet, then the fork can accommodate pallet tilting, but the fork may not be positioned at the center of the pallet due to variations in pallet detection and fork control, leading to picking up failure
Solution Approach 1:
The control device performs preliminary detection of the pallet's position and tilt state before fork insertion. Based on the detection results, the system pre-adjusts the fork's tilt angle and vertical position to compensate for expected misalignment, ensuring the fork is properly positioned before attempting insertion.
Solution Approach 2:
The system uses sensors to detect the actual position of the fork relative to the pallet walls during insertion. This detection information is fed back to the control device, which then adjusts the tilt cylinder and lift cylinder in real-time to correct positioning errors and ensure successful insertion despite variations in pallet detection or fork control.
2Measurement precision
If the fork is controlled to move up and down to offset height changes from tilting control, then the height of the fork at the entrance of the pallet insertion hole can be maintained, but this may delay the insertion process when the pallet is tilted
Solution Approach 1:
The control device calculates the required vertical adjustment amount based on the detected pallet tilt angle before fork insertion begins. The lift cylinder is pre-positioned to the appropriate height, eliminating the need for slow iterative adjustments during the insertion process itself.
Solution Approach 2:
The system dynamically adjusts the fork's vertical position based on real-time detection of pallet tilt. Rather than using fixed pre-adjustment values, the lift cylinder continuously adapts its position according to the actual pallet orientation, maintaining precision while accommodating variations in pallet placement.
Data Source
AI summary
A cargo handling control device of a forklift truck including a lift cylinder, and a tilt cylinder. The cargo handling control device includes an approach distance detector, an insertion controller, an insertion amount calculator, a pre-insertion determination unit, a first fork operation controller, and a second fork operation controller. The first fork operation controller causes the fork to move up and down toward a center of the pallet in a height direction of the pallet in a case where the tip portion of the fork is determined to be in the pre-insertion state. The second fork operation controller causes the fork to tilt to be positioned along an inner wall surface of an upper wall or a lower wall of the pallet and the fork to move up and down in the case where the tip portion of the fork is determined to be in a post-insertion state.