Forklift Mast Scale for Accurate Pallet Height Measurement
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Solution Overview
Problem
Current dynamic routing systems for pallet transport rely on supplier-provided height information, leading to inefficiencies due to overestimation, and lack accurate height data during milkrun distributions where central scanning is not available, resulting in suboptimal truck space utilization and planning inefficiencies.
Innovation Solution
Equipping trucks with a forklift and a handheld scanning device, where the forklift has a mast with a scale and unique codes to measure and confirm the actual pallet height, allowing real-time data transmission to the dynamic routing system for improved planning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If supplier-provided height information is used for dynamic routing planning, then the planning process is simple and quick, but the accuracy of height data is low leading to suboptimal truck space utilization
Solution Approach 1:
The forklift driver themselves performs the height measurement using the scale on the mast, eliminating the need for separate measurement devices or personnel. The driver reads the height directly from the scale and inputs it into the handheld device, making the system self-sufficient and operationally simple while achieving accurate measurements.
Solution Approach 2:
The forklift mast scale serves multiple functions: it provides height measurement for routing planning, enables space optimization calculations, and integrates with the existing forklift operation. The handheld scanning device also serves dual purposes for both barcode scanning and height data input, reducing overall system complexity.
2Measurement precision
If central distribution system scanning is used to obtain accurate pallet height, then height measurement accuracy is high, but the measurement can only be performed after arrival at central distribution, reducing planning efficiency
Solution Approach 1:
The height measurement is performed preliminarily at the collection point before the pallet is loaded onto the truck. The driver measures and inputs the height data using the forklift mast scale and handheld device, so the accurate height information is available in advance for routing planning, eliminating the need to wait until central distribution.
Solution Approach 2:
The forklift mast scale acts as an intermediary measurement tool that bridges the gap between the collection point and central distribution system. It provides accurate height measurements at the source, and the handheld scanning device serves as an intermediary for data capture and transmission to the dynamic routing system.
3Productivity
If conservative height estimates are used for routing planning, then truck space optimization is improved, but the productivity is reduced due to fewer pallets being stacked vertically
Solution Approach 1:
The system implements feedback by capturing actual height measurements at the collection point and using this reliable data for routing planning. The dynamic routing system receives accurate height information from the handheld device and adjusts the stacking plan accordingly, allowing for optimized truck space utilization without compromising reliability.
Data Source
Figure 1
Figure 2~3
AI summary
A combination of a forklift and a hand held scan device, which forklift comprises an elongate measurement device arranged to the mast of the forklift in longitudinal direction, which elongate measurement device comprises: - a main scale extending in longitudinal direction; - a plurality of unique codes scannable by the hand held scan device, wherein the unique codes are arranged along the scale at a fixed pitch.