Forklift Loading Control Device for Pallet Position Detection
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Solution Overview
Problem
Existing loading control devices require forklift trucks to travel around the loading platform to detect its position, increasing the traveling distance and loading time.
Innovation Solution
A loading control device that includes a pallet presence detector, a pallet detector, a loading position calculator, and a loading controller to determine the position of a pallet on the loading platform and calculate a next loading position next to the existing pallet in the lateral direction, reducing the need for the forklift truck to travel around the platform.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the forklift truck travels along the edge of the loading platform to detect it, then the loading platform position can be detected, but the traveling distance increases
Solution Approach 1:
The patent introduces an intermediary object (marker or reflector) placed on the loading platform that serves as a mediator between the forklift's detection system and the platform itself. This intermediary reflects or emits signals that enable the forklift to detect the platform's position and calculate the loading position without needing to travel along its edge, thus resolving the contradiction between detection accuracy and travel distance
Solution Approach 2:
The loading position is calculated in advance based on the detected platform position and stored as reference data. This preliminary calculation eliminates the need for the forklift to perform real-time detection by traveling along the platform edge during the actual loading operation, significantly reducing travel distance while maintaining detection precision
2Reliability
If the forklift truck travels around the loading platform to detect it, then the loading platform can be located, but the loading time increases
Solution Approach 1:
The patent replaces the mechanical detection method (forklift physically traveling along the platform edge) with an optical or electromagnetic detection system using markers, reflectors, or sensors. This substitution allows the forklift to detect the platform position from a distance without mechanical contact or extensive movement, thereby maintaining reliable location detection while significantly reducing loading time and improving productivity
3Manufacturing precision
If the forklift truck needs to travel around the loading platform, then the loading position can be determined, but the operating efficiency decreases
Solution Approach 1:
The system implements feedback by continuously monitoring the forklift's position relative to the loading platform using detected markers or reflectors. Based on this feedback, the control system automatically adjusts the forklift's movement and calculates the optimal loading position, eliminating the need for preliminary travel-around detection while maintaining high positioning precision and improving operating efficiency
Data Source
AI summary
A loading control device includes: a pallet presence detector configured to determine whether a pallet is present on a loading platform; a pallet detector configured to detect a position of the pallet present on the loading platform when the pallet presence detector determines that the pallet is present on the loading platform; a loading position calculator configured to calculate a loading position for another pallet to be loaded onto the loading platform next after the pallet present on the loading platform based on the position of the pallet present on the loading platform; and a loading controller configured to control a forklift truck so that the pallet is loaded at the loading position. The loading position calculator calculates a position next to the pallet present on the loading platform in a lateral direction of the forklift truck as the loading position.