Forklift Fork Proximity Sensor Avoidance Control
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Solution Overview
Problem
Existing forklift technologies face challenges in properly inserting forks into pallet insertion openings due to sensors detecting proximity with facing surfaces, leading to improper pallet mounting.
Innovation Solution
A forklift system equipped with sensors in the insertion portion to detect proximity with facing surfaces, featuring a stopping process and an avoidance process that control the tilt and lift devices to separate the forks from the facing surfaces without changing their position relative to the insertion opening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the forklift uses sensors to detect proximity with facing surfaces to prevent contact, then the reliability of pallet mounting is improved, but the complexity of the control system increases due to multiple sensors and processing circuitry
Solution Approach 1:
The system performs preliminary detection using sensors (first sensor at distal end, second sensor at distal end, third sensor at proximal end, fourth sensor at proximal end) to identify potential contact with facing surfaces before actual contact occurs. This allows the control system to execute avoidance processes in advance, preventing harmful contact while maintaining reliable pallet mounting.
Solution Approach 2:
The control system acts as an intermediary between the sensors and the lift/move devices. It processes sensor signals and coordinates the avoidance process by controlling the lift device and move device to separate the forks from facing surfaces when contact is detected, thereby managing the complexity through centralized control logic.
2Manufacturing precision
If the forklift executes avoidance process to separate forks from facing surfaces, then the manufacturing precision of insertion is improved, but the time required for insertion operation increases
Solution Approach 1:
The avoidance process is activated only partially - specifically when sensors detect proximity to facing surfaces. The system applies the avoidance action (separating forks via lift device and move device) only when and where needed, rather than continuously, thereby maintaining precision while minimizing time loss during normal insertion operations.
Solution Approach 2:
The system rushes through the avoidance process by quickly executing the separation maneuver when contact is detected, then immediately resuming the insertion operation. This minimizes the time spent in the avoidance state while still achieving the necessary separation to prevent contact with facing surfaces.
3Reliability
If the forklift stops movement when sensors detect proximity state, then the reliability of preventing harmful contact is improved, but the productivity of the insertion process decreases
Solution Approach 1:
The system uses periodic sensor detection to monitor proximity to facing surfaces during the insertion process. The sensors continuously detect the state, and the control system periodically evaluates whether avoidance action is needed, allowing the forklift to maintain high productivity by only stopping when actually necessary rather than continuously halting.
Solution Approach 2:
The sensor system provides real-time feedback about the proximity state to the control system. This feedback mechanism allows the forklift to make informed decisions about when to stop and execute avoidance processes, ensuring reliable contact prevention while maintaining productivity by avoiding unnecessary stops based on accurate sensor information.
Data Source
AI summary
A forklift includes a vehicle body, a fork that mounts a pallet, and a sensor provided in an insertion portion of the fork. The forklift inserts the insertion portion into an insertion opening, while moving the fork. When the sensor detects a proximity state, in which the insertion portion has approached a facing surface to such an extent that a distance between the insertion portion and the facing surface is less than or equal to a specified value, the forklift executes a stopping process that stops movement of the fork. The forklift executes an avoidance process that tilts and vertically moves, after the stopping process, the fork to separate the insertion portion away from the facing surface such that a position of the insertion portion with respect to an entrance of the insertion opening does not change in an up-down direction of the vehicle body.