Forklift Lifting Height Preselection via Automatic Inclination Control
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Solution Overview
Problem
Existing lifting height preselection systems in industrial trucks are time-consuming and ergonomically inefficient, requiring drivers to manually select from numerous programmed heights while unable to operate the lifting hydraulics simultaneously, leading to reduced handling capacity and increased errors.
Innovation Solution
A method that displays and allows intuitive selection of the next reached lifting height using a switching element on the operating element, enabling simultaneous operation of the lifting movement and automatic adjustment of the load-carrying device's inclination, eliminating the need for manual compartment selection and reducing ergonomic strain.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large number of storage heights are programmed into the control computer to cover different warehouse areas, then the system can handle more storage locations, but the time required to select the correct lifting height increases significantly
Solution Approach 1:
The control system segments the selection process into two stages: first selecting a storage area (coarse selection), then selecting a specific shelf within that area (fine selection). This hierarchical segmentation reduces the cognitive load and time required to select from a large number of storage locations by breaking down the complex selection task into manageable steps.
Solution Approach 2:
The system performs preliminary action by pre-grouping storage heights into defined areas with specific height ranges. When a driver selects an area, the system has already prepared the relevant subset of lifting heights for that area, eliminating the need to process all 160 storage heights simultaneously and reducing selection time.
2Ease of operation
If the driver uses the control panel to select storage area and shelf compartment, then the lifting height can be preselected, but the driver cannot simultaneously operate the lifting hydraulics, resulting in delays
Solution Approach 1:
The system introduces an intermediary automatic selection function that mediates between the driver's area selection and the specific shelf selection. When the driver selects an area and triggers the automatic selection, the control computer automatically determines the appropriate shelf within that area based on stored parameters, eliminating the need for manual shelf selection and allowing simultaneous hydraulic operation.
Solution Approach 2:
The control system performs self-service by automatically selecting the specific shelf compartment within a chosen area based on pre-stored warehouse configuration data. This automatic selection eliminates the need for the driver to manually input the shelf number, allowing the driver to continue operating the lifting hydraulics without interruption and maintaining productivity.
3Measurement precision
If the driver reads compartment numbers from distance and enters them at the dashboard, then the correct storage location can be identified, but the workflow becomes non-ergonomic and time-consuming
Solution Approach 1:
The system replaces the mechanical workflow of reading physical compartment numbers and manually entering them with an electronic automatic selection system. The control computer automatically retrieves and inputs the shelf number based on the selected area and stored warehouse data, eliminating the need for the driver to perform the ergonomic strain of reading and typing while maintaining accurate location identification.
4Manufacturing precision
If the load fork inclination is manually adjusted by the driver, then the load can be properly positioned, but the driver cannot see the load fork well at large heights and delays occur
Solution Approach 1:
The system implements self-service by automatically adjusting the load fork inclination based on the selected storage location and lift height. The control computer calculates the required inclination angle and actuates the inclination mechanism automatically, eliminating the need for manual adjustment and allowing the driver to maintain visual contact with the load fork while achieving precise positioning.
5Reliability
If the mast bending and elasticity are compensated for during automatic alignment, then the load fork inclination can be maintained, but the complexity of the control system increases
Solution Approach 1:
The system uses feedback by continuously monitoring the actual load fork inclination during the lifting process and comparing it with the target inclination. Based on this feedback, the control system automatically makes real-time adjustments to compensate for mast bending and elasticity effects, maintaining accurate load positioning without requiring complex mechanical modifications to the lifting mechanism.
Data Source
Figure 1~2
AI summary
In a method for preselecting the lifting height of a forklift truck (8) with a load handling device (15) which is guided vertically on a lifting mast (14), with a control device, a display device and an operating element for controlling a lifting movement by an operator, during a lifting movement the control device displays the next reached, stored lifting height in the display device and when a switching element arranged on the operating element for the lifting movement is actuated, this lifting height is selected by the control device.