Forklift Mast Cable Storage With Rigid Winding Elements
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Solution Overview
Problem
Industrial trucks require flexible electrical cabling to accommodate varying mast lengths, leading to high manufacturing costs, logistical complexity, and assembly inefficiencies due to vehicle-specific cable sets, with excess length cables at risk of damage and requiring complex storage solutions.
Innovation Solution
A cable storage device with fixed, rigid winding elements attached to the lifting mast, allowing excess cable length to be wound safely and orderly, using a housing with multiple winding elements that can be adjusted for different mast lengths, reducing construction costs and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate connecting cable set is provided for each mast length, then the electrical cabling is adapted to the corresponding mast length, but manufacturing costs increase and logistical effort becomes significant
Solution Approach 1:
A single universal connecting cable set design is used across all mast lengths within a forklift series. The cable set is designed to accommodate the longest mast length, and for shorter masts, the excess cable is wound around a winding element. This universal approach eliminates the need for multiple vehicle-specific cable sets, reducing manufacturing complexity and logistical effort while maintaining proper cable length adaptation for each application.
Solution Approach 2:
The excess length of the connecting cable is stored by winding it around a winding element that is integrated into the cable storage unit. This nesting approach allows the cable to be compactly stored within the existing cable storage structure without requiring additional external components or complex winding mechanisms, thereby simplifying the overall system while solving the cable length adaptation problem.
2Adaptability or versatility
If a connecting cable set matched to the longest-length mast is used, then all mast lengths can be covered, but the excess length must be wound up and secured which is time-consuming
Solution Approach 1:
The winding element is pre-integrated into the cable storage unit housing, which is itself pre-mounted to the lifting mast. This preliminary preparation eliminates the need for assembly personnel to separately install winding mechanisms or complex securing structures during cable installation. The cable can be directly wound around the pre-positioned winding element and secured using the integrated retaining features, significantly reducing assembly time while maintaining adaptability across all mast lengths.
3Ease of operation
If the wound connecting cable set is loosely attached to the mast, then it can be stored, but it is at risk of damage and being driven off
Solution Approach 1:
The winding element is merged with the cable storage unit housing, creating an integrated assembly where the cable is wound around the winding element and retained within the housing structure. This combination eliminates the need for separate loose attachment mechanisms and provides inherent cable protection through the housing enclosure, which prevents damage and secures the cable against being driven off while maintaining ease of operation through simple cable winding and retention.
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
The invention relates to a forklift truck (1) comprising a vehicle body (2) and a lifting mast (3) on which a load-handling device (4) is arranged for raising and lowering, wherein an electrical connection cable set (5) is provided, comprising at least one electrical connection cable (6) which is led from the vehicle body (2) to at least one electrical component arranged on the lifting mast (3) or on the load-handling device (4), wherein a cable storage unit (10) is provided on the lifting mast (3) for receiving the electrical connection cable (6). The cable storage unit (10) has a housing (11) that can be attached to the lifting mast (3), in which at least two spaced-apart winding elements (12a; 12b; 12c; 12d), on which the connection cable (6) can be wound, can be fixedly and rigidly attached.