Lift Height Measurement Optical Alignment for Forklifts
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Solution Overview
Problem
Existing lift-height measurement systems in industrial trucks face issues such as mechanical wear, tearing of ropes, and difficulty in maintaining accurate absolute measurements due to bending or twisting of the mast, which leads to errors in height calculation and requires complex signal lines and power supplies.
Innovation Solution
A light emitter and receiving element system with an optical alignment element and target element, where the light beam is tracked to maintain alignment with the target element, allowing for absolute height measurement using a compact and robust design that avoids mechanical wear and eliminates the need for cables or additional electrical lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a laser distance sensor is used for absolute height measurement, then measurement precision is improved, but the target element must be dimensioned large to account for mast bending, which increases device complexity and space requirements
Solution Approach 1:
The patent applies the dynamics principle by making the alignment element movable rather than fixed. The alignment element can dynamically adjust its position and orientation to track the target element even when the mast bends or shifts during operation. This dynamic adjustment capability allows the system to maintain measurement precision without requiring an oversized static target element, thus resolving the contradiction between measurement accuracy and device complexity.
2Ease of manufacture
If cables or ropes are used for height measurement, then ease of manufacture is improved, but reliability deteriorates due to mechanical wear, tearing, and entanglement
Solution Approach 1:
The patent replaces the mechanical cable/rope-based measurement system with an optical measurement system using a laser distance sensor. This substitution eliminates the mechanical wear, tearing, and entanglement problems associated with cables and ropes while maintaining ease of manufacture. The optical system requires no physical contact with moving parts, thus significantly improving reliability without sacrificing manufacturing simplicity.
3Device complexity
If incremental height measurement is used, then device complexity is reduced, but measurement precision deteriorates due to accumulating errors
Solution Approach 1:
The patent employs an absolute laser distance measurement system that directly measures the total height from a reference point rather than accumulating incremental changes. This approach maintains relatively simple device complexity while eliminating the error accumulation problem inherent in incremental measurement systems. The laser sensor provides direct absolute position data, ensuring high measurement precision without requiring complex error correction mechanisms.
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
Enables precise and reliable absolute height measurement in industrial trucks, even with high lifting heights, by tracking the light beam and maintaining alignment, reducing errors and mechanical wear, and simplifying integration with existing laser distance sensors.
Implementation Method 1
a light emitter (21) emitting a light beam (23), a receiving element (21) and a measuring section (29) arranged between these
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The truck (2) i.e. counterbalance fork-lift truck (1), has a load-carrying equipment (13) i.e. loading fork (12), movably arranged at a multi-lift frame (11). The lift frame comprises a lifting height measurement system that comprises light emitters i.e. lasers, for emitting a light beam. A measuring section is provided with an optical alignment element and an objective element (18). The alignment element is movably supported and adjusts the light beam by a position of the objective element. The light beam departing the receptor element is recognized by a signal of the objective element. An independent claim is also included for a method for measuring lifting height of an industrial truck.