Forklift Fork Positioning With Acceleration-Guided Light Mark
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Solution Overview
Problem
Fork-lift machine operators face difficulties in safely positioning the forks under loads due to limited space and reduced visibility, leading to inefficiencies and potential product damage, with existing solutions being cumbersome, inadequately protected, and lacking in functionality and adjustability.
Innovation Solution
A method and device that activates a light beam based on measurements of the total acceleration vector of the forks, including gravity and displacement vectors, to guide the operator during the loading process, using a compact electronic unit with an accelerometer and programmable microcontroller to control the light beam's activation and modulation according to specific handling steps and fork angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a light mark assistance device is installed on the fork-lift machine, then the driver can better assess the relative position of the forks with respect to the load, but the installation and settings are neither easy nor rapid
Solution Approach 1:
The device merges multiple functions into a single integrated unit: the light mark emitter, accelerometer, microcontroller, and power supply are combined in one compact device that mounts directly to the fork-lift machine. This eliminates the need for separate installation of multiple components and simplifies the overall setup process while maintaining precise position assessment capabilities
Solution Approach 2:
The device automatically activates the light mark based on acceleration measurements without requiring manual intervention or complex configuration. The microcontroller processes accelerometer data to detect when the forks are in the correct position and automatically controls light mark emission, eliminating the need for manual settings adjustment during operation
2Measurement precision
If existing light mark devices are used, then position guidance is provided, but the device is inadequately protected from possible collisions with the loads to be handled
Solution Approach 1:
The device is mounted on the vertical mast structure of the fork-lift machine rather than on the horizontal fork arms, positioning it in a different spatial dimension that is less susceptible to collision with loads. This elevated mounting position protects the sensitive electronic components while maintaining the ability to project light marks onto the load for position guidance
3Loss of information
If the light beam is continuously activated, then the driver always has position information, but the autonomy of the device is penalized when powered by batteries
Solution Approach 1:
Instead of continuous light beam activation, the system uses periodic activation triggered by acceleration events. The microcontroller monitors accelerometer data and activates the light mark only when fork movement is detected, providing position information when needed while conserving battery energy during stationary periods
Solution Approach 2:
The system uses feedback from the accelerometer to control light mark activation. The microcontroller continuously monitors acceleration data and automatically activates or deactivates the light beam based on the detected motion state, ensuring position information is available during active handling while minimizing energy consumption during idle periods
4Productivity
If the driver has to search for loads at height, then the full handling capability is utilized, but time is lost and visibility is reduced due to the mast and apron
Solution Approach 1:
The light mark is activated in advance to indicate the target position on the load before the forks reach it. This preliminary visual guidance allows the driver to prepare for the insertion action, reducing the time needed to search and position the forks correctly at height while maintaining full handling 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 the safety and efficiency of load handling by providing precise positioning guidance, reducing operator errors and product losses, while being easy to install and maintain, with improved protection and adjustable functionality.
Implementation Method 1
the measurement of the total acceleration vector acting on the forks, said total acceleration vector being by its nature the resultant of the gravity acceleration vector and of the displacement vector of the forks
Implementation Method 2
an accelerometer, said accelerometer continuously measuring the total acceleration vector acting on the forks
Implementation Method 3
a module for emitting a light beam, said light beam allowing to generate a light mark on the load
Data Source
AI summary
A method and device allowing a driver of a handling machine of the forklift type to position and introduce, in complete safety, the forks of the machine under a load to be handled. A light-beam that projects a luminous mark onto the load to be handled informs the driver of the relative position of the forks with respect to the load to be handled. The light-beam is activated and adjusted depending on the different steps of handling and inclination of the forks, which, for their part, are identified solely on the basis of the measurement of the acceleration acting on the forks. The device, which is installed quickly and protected effectively against collisions, has a high degree of operational autonomy. It improves working conditions and reduces product losses.