Forklift Load Contour Scanning During Transport
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Solution Overview
Problem
Existing methods for checking the contours of loads on industrial trucks require additional handling steps and are time-consuming, as they necessitate transferring the load to a separate checking station or conveyor belt, which can lead to inefficiencies and increased risk of damage or accidents during logistics handling.
Innovation Solution
A device comprising a drivable surface and at least two sensor units that record two-dimensional data to check the load's contour in real-time during transport, allowing for continuous monitoring without the need for additional handling steps, using laser scanners or similar technology to ensure the load adheres to predetermined dimensions and safety zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the load contour is checked using a stationary checking station or conveyor belt, then the contour can be verified, but additional handling steps and time are required
Solution Approach 1:
The patent combines the contour checking function with the existing transport path by installing sensor units along the drivable surface. This merging eliminates the need for separate checking stations or conveyor belts, as the contour verification is performed during the normal transport process, thereby reducing handling time while maintaining measurement precision
Solution Approach 2:
The sensor units continuously monitor the load contour during transport without interrupting the workflow. The checking process occurs continuously as the industrial truck moves along the drivable surface, eliminating the need to stop or transfer loads to dedicated checking equipment, thus maintaining continuous productive action
2Reliability
If the load is transferred to a separate checking station, then contour control can be performed, but additional handling steps increase the risk of damage or accidents
Solution Approach 1:
The patent extracts the contour checking function from the mechanical handling process and implements it through optical sensor units. By taking out the physical transfer step and replacing it with optical measurement during transport, the system maintains reliable contour control while eliminating the harmful effects associated with additional handling and transfer operations
Solution Approach 2:
The patent replaces the mechanical transfer system (conveyor belts or manual handling at checking stations) with an optical measurement system. Laser scanners and camera systems capture contour data during transport, substituting mechanical interaction with optical field-based measurement, thereby maintaining control reliability while reducing physical handling risks
3Measurement precision
If traditional checking methods are used, then contour verification is possible, but productivity is reduced due to additional work steps
Solution Approach 1:
The sensor units are pre-positioned along the drivable surface to perform contour checking during the inevitable transport movement. By preparing the measurement system in advance and utilizing the transport motion itself as the checking mechanism, the system achieves accurate contour verification without adding separate checking steps, thereby maintaining productivity
Solution Approach 2:
The sensor units serve multiple functions: they monitor contour dimensions, verify load stability, and can detect potential hazards during transport. This multi-functionality is achieved within the existing transport infrastructure, eliminating the need for dedicated single-purpose checking equipment and maintaining logistics throughput while enhancing measurement capabilities
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 rapid and precise contour checking of loads during transport, reducing the risk of damage or accidents by integrating the control process into existing logistics operations, saving time and minimizing staffing requirements, while ensuring loads are within safe geometric dimensions.
Implementation Method 1
using laser scanners or similar technology to ensure the load adheres to predetermined dimensions and safety zones
Data Source
Figure 1~2
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Figure 5~6
AI summary
The present invention relates to a device (10) for checking the contour of a load (L) picked up on a forklift truck (100), comprising a surface (12) traversable by the forklift truck (100), at least two sensor units (16a, 16b) wherein the sensor units (16a, 16b) are configured to record two-dimensional data and are arranged such that a substantially vertical detection area (14) is defined, and a control device (20) which is configured to specify and/or determine the relative position of the forklift truck (100) located on the traversable surface (12) with respect to the detection area (14).and at least one evaluation unit (18) configured to evaluate the data recorded by the sensor units (16a, 16b) to determine whether the area occupied in the detection range (14) by the industrial truck (100) and/or the load (L) it carries fulfills a predetermined condition, taking into account the relative position. Furthermore, the invention relates to a system formed by such a device (10) and at least one industrial truck (100), as well as a method for checking the contour of a load picked up from the industrial truck in such a system;