Forklift Load Diagram Segmentation for Tipping Hazard Reduction
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Solution Overview
Problem
Current methods for displaying permissible loads on industrial trucks, such as forklifts, often represent three-dimensional data in a way that is not easily readable or intuitive, leading to potential overloading and tipping hazards due to unclear representation of load moment and lifting height dependencies.
Innovation Solution
A load diagram is displayed with a lifting height scale on the Y-axis and load torque value scale on the X-axis, featuring a vertical line for the maximum permissible load moment, a limit curve for lifting height, and a bar chart for load moment, allowing quick recognition of permissible values and providing real-time measurements and warnings for safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If a load diagram displays multiple two-dimensional lines for different center of gravity positions, then the three-dimensional characteristic map is represented, but the reading speed and intuitiveness are hindered
Solution Approach 1:
The load diagram is segmented into distinct visual elements: a limit curve representing the three-dimensional characteristic map, vertical lines representing maximum permissible load moments for different center of gravity positions, and a bar chart showing available load moment. This segmentation allows the complex three-dimensional data to be broken down into manageable visual components that can be processed more quickly and intuitively.
Solution Approach 2:
The patent transforms the three-dimensional characteristic map into a two-dimensional limit curve on the load diagram. By projecting the three-dimensional relationship between load moment, lifting height, and center of gravity position onto a two-dimensional plane, the diagram maintains completeness while improving readability. The bar chart adds another dimensional representation to show the available load moment as a proportion of the maximum permissible load moment.
2Reliability
If the load diagram uses traditional representation methods, then the specifications must be adhered to, but the operator is often unaware of the actual dimensions and load moment
Solution Approach 1:
The bar chart uses color coding to represent the available load moment as a proportion of the maximum permissible load moment. Different colors can indicate different levels of load capacity, making it easier for operators to quickly assess whether a load is safe to lift. This visual encoding of information enhances operator awareness without compromising the reliability of the safety specifications.
Solution Approach 2:
The patent introduces intermediate visual elements (vertical lines for maximum permissible load moments, bar chart for available load moment) that mediate between the raw three-dimensional data and the operator's understanding. These intermediaries translate complex load moment calculations into intuitive visual representations, enabling operators to quickly grasp the actual dimensions and load moment without compromising safety.
3Loss of information
If the load diagram displays detailed three-dimensional characteristics, then the completeness of load information is maintained, but the complexity of the diagram increases
Solution Approach 1:
The complex three-dimensional characteristic map is segmented into distinct visual components: the limit curve, vertical lines for maximum permissible load moments, and the bar chart. This segmentation reduces the perceived complexity by organizing the information into separate, easily processable elements rather than a single complex graph.
Solution Approach 2:
The patent extracts key information from the three-dimensional characteristic map and presents it separately through the bar chart, which shows the available load moment as a proportion of the maximum permissible load moment. This extraction allows the main limit curve to remain simple while additional details are provided through the bar chart, reducing overall diagram complexity while maintaining information completeness.
Data Source
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Figure 3~5
AI summary
The method involves determining position of a balance point of a load regarding length of a load accommodation unit i.e. load fork. A load moment is determined from the balance point. A limit curve (15) for vertical lift line is represented depending on the load moment, where a load diagram has vertical lift scale as y-axis and load moment value scale as x axis. A tolerable load moment (14) is represented by an intersection point of a vertical lift line with the limit curve through a perpendicular load line (16). An independent claim is also included for a floor conveyor comprising a lift frame.