Forklift Fork Tilt Control for Inclined Pallet Unloading
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing unloading systems face challenges in smoothly removing forks from a pallet when unloading cargo from a loading portion inclined in the pitch direction, as the forks often get caught on the inner wall surface of the pallet.
Innovation Solution
An unloading control device that includes a pallet detection unit, a tilt angle detector, a lowering control unit, a change amount estimation unit, a determination unit, a tilting control unit, and a withdrawing control unit, which work together to detect the pallet, estimate the change in its posture, determine if it has abutted on the loading portion, tilt the forks to be parallel to the pallet, and then withdraw the forks smoothly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the forklift unloads cargo from an inclined loading portion, then the unloading operation can be performed, but the forks get caught on the inner wall surface of the pallet
Solution Approach 1:
The system performs preliminary detection of the pallet's posture and position, and preliminarily adjusts the forks' tilt angle before the withdrawal action. By detecting the pallet's inclination angle in advance and pre-adjusting the forks to match this angle, the system ensures smooth fork removal without catching on the pallet's inner wall surface.
Solution Approach 2:
The system continuously detects the pallet's posture and position during the unloading process, and uses this feedback information to dynamically adjust the forks' tilt angle. The tilt angle detector and pallet detection unit provide real-time feedback that enables the control unit to optimize the forks' orientation for smooth withdrawal from the pallet.
2Speed
If the forks are removed directly from an inclined pallet, then the unloading is faster, but the forks contact the inner wall surface causing operational problems
Solution Approach 1:
Before the rapid withdrawal phase, the system performs preliminary detection of the pallet's inclination and pre-adjusts the forks' tilt angle to match. This preliminary alignment ensures that when the forks are quickly removed, they follow the pallet's inclination and avoid contacting the inner wall surface, maintaining both speed and reliability.
Solution Approach 2:
The system uses real-time feedback from the pallet detection unit and tilt angle detector to dynamically adjust the forks' orientation during withdrawal. This feedback mechanism ensures that even at high speeds, the forks maintain the correct angle relative to the inclined pallet, preventing contact with the inner wall surface.
Data Source
AI summary
Provided is an unloading control device includes a determination unit configured to determine whether or not the pallet held by the forks abuts on an upper surface of the loading portion based on the change amount of the posture of the pallet with respect to the forks estimated by the change amount estimation unit, a tilting control unit configured to control a tilt cylinder of the forklift so that the forks tilt in a direction approaching parallel to a main surface of the pallet when the determination unit determines that the pallet held by the forks abuts on an upper surface of the loading portion, and a withdrawing control unit configured to control the forklift so as to remove the forks from the pallet according to the tilt angle of the forks detected by the tilt angle detector after the forks approach parallel to the main surface of the pallet.