Forklift Fork Sensor Layout for Pallet Offset and Tilt Detection
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Solution Overview
Problem
Forklifts face challenges in safely and accurately positioning pallets on forks to prevent unfavorable load distribution and ensure operational safety, particularly in autonomous or automated systems where precise pallet positioning is crucial for reliable operation.
Innovation Solution
A method and forklift truck design that utilizes multiple distance measuring devices to determine the pose of a pallet relative to the forks, calculating offset and tilt measurements to ensure the pallet is centered and aligned before lifting, using sensors like laser and lidar to monitor continuous position changes and adjust steering and lifting accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple distance measuring devices are used to determine pallet position and orientation, then measurement precision and operational safety are improved, but device complexity increases
Solution Approach 1:
The system divides the measurement task into multiple independent distance measuring devices, each responsible for measuring distance to specific reference points on the pallet (front reference point, rear reference point, side reference points). This segmentation allows parallel measurement of multiple parameters simultaneously, improving overall measurement precision without requiring a single complex measuring system.
Solution Approach 2:
The distance measuring devices serve multiple functions: they measure distances to different reference points on the pallet, determine both position offset and orientation tilt, and provide data for both safety verification and positioning control. This multi-functionality reduces the need for separate specialized devices for each measurement task.
2Measurement precision
If distance measurements are taken during the entire entry process, then position determination accuracy is improved, but loss of time due to continuous measurement and calculation increases
Solution Approach 1:
The system performs distance measurements continuously during the pallet entry process, gathering measurement data in advance before the lifting operation begins. This preliminary measurement action ensures that position and orientation data are already available and verified before the critical lifting phase, improving accuracy without delaying the main operation.
Solution Approach 2:
The system rapidly processes measurement data during the entry process and makes quick determination of pallet position and orientation. Once the pallet is sufficiently inserted and measurements confirm proper positioning, the system quickly transitions to the lifting phase, minimizing the time spent on measurement and calculation while ensuring accuracy requirements are met.
3Reliability
If offset and tilt measurements are calculated from multiple distance measurements, then reliability of pallet positioning is improved, but device complexity and calculation requirements increase
Solution Approach 1:
The control device continuously calculates offset and tilt measurements from the distance measuring devices and uses this feedback information to monitor pallet positioning accuracy. The system compares calculated values against acceptable thresholds and can trigger alerts or corrections if positioning deviations are detected, improving reliability through continuous verification.
Solution Approach 2:
The system replaces complex mechanical positioning and measurement mechanisms with optical or electromagnetic distance measuring devices and computational calculations. Instead of using mechanical gauges or physical alignment tools, the system uses distance measurements and mathematical calculations to determine pallet position and orientation, reducing mechanical complexity while improving measurement capability.
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
Enhances operational safety by ensuring pallets are centrally and straightly positioned on forks, preventing unsafe lifting and improving the reliability of autonomous pallet handling operations.
Implementation Method 1
A first distance measuring device (6) is arranged in the region of a fork tip of the first fork tine (3) and is directed towards the space between the forks (3, 4) or outwards
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
A method for determining the position of a pallet relative to a forklift, which has a pair of forks with a first and second fork tine and a first distance measuring device arranged in the region of a fork tip on the first fork tine and preferably directed towards a fork gap, wherein the pallet has an outer block, outer web, middle block or web, characterized by the steps: • Driving the forklift into the pallet so that the first and second fork tines penetrate the pallet, • Determining several first distance measurements with the first distance measuring device to the outer block, outer web, middle block or web of the pallet during entry, • Calculating an offset measurement from at least one first distance measurement and/or an inclination measurement from the difference of at least two first distance measurements.