Forklift Protective Zone Verification Through Load Carrier Lift Tests
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Solution Overview
Problem
Current methods for ensuring that the load and protective fields of industrial trucks match are complex and require on-site testing after delivery, which is inefficient and prone to errors.
Innovation Solution
An automatic method for testing protective zones on industrial trucks using vehicle-mounted monitoring devices, such as laser scanners, to check for violations by lifting a load carrier and ensuring all protective zones are clear before operation, with error correction and blocking automatic operation if errors occur.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If on-site testing with precisely positioned test objects is used to ensure load and protective field width match, then measurement precision is improved, but device complexity and time consumption increase
Solution Approach 1:
The patent uses a virtual model of the load carrier that is copied from the actual load carrier data. This virtual model is then used in the simulation to test protective zone violations, eliminating the need for physical test objects and complex on-site positioning equipment while maintaining measurement precision.
Solution Approach 2:
The patent replaces the mechanical testing system (physical test objects, positioning equipment, manual measurement tools) with a computer-based simulation system. The simulation digitally recreates the load carrier and protective zones, allowing for automated verification without complex physical setup.
2Measurement precision
If on-site testing with precisely positioned test objects is used to ensure load and protective field width match, then measurement precision is improved, but loss of time increases
Solution Approach 1:
The patent performs preliminary actions by creating a virtual model of the load carrier and pre-defining protective zone parameters before the actual testing process. The simulation can then quickly evaluate multiple scenarios without requiring time-consuming physical setup and positioning of test objects on-site.
Solution Approach 2:
By replacing the mechanical testing process with a computer simulation, the patent eliminates the time required for physical setup, positioning, and manual measurement. The simulation can rapidly evaluate protective zone configurations digitally, significantly reducing testing duration while maintaining precision.
3Productivity
If automated testing of protective zones is implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The patent implements a universal testing system that can handle multiple load carrier types and protective zone configurations through a single simulation platform. The system uses standardized data interfaces and can adapt to different scenarios, providing high productivity without requiring separate complex equipment for each testing case.
Solution Approach 2:
The simulation creates virtual copies of load carriers and protective zones that can be repeatedly tested without physical equipment. This digital copying approach enables automated batch testing of multiple configurations, significantly improving productivity while the software handles the complexity of managing various test scenarios.
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
Ensures efficient, error-free checking of protective zones during operation, commissioning, or service appointments, preventing collisions and ensuring safe automatic operation by identifying and correcting protective zone violations.
Implementation Method 1
at least one vehicle-mounted monitoring device (13), in particular a laser scanner
Data Source
Figure 1
Figure 2
AI summary
A method for automatically checking at least one protective zone on a forklift truck equipped with at least one vehicle-mounted monitoring device that monitors a protective zone laterally and/or in front of the forklift truck and indicates a protective zone violation if an object or person is located in the protective zone, wherein the method comprises the following steps: • Activating the at least one protective zone on the forklift truck, • Picking up and lifting a load carrier, • Checking whether the protective zone(s) are clear, • Lowering the load carrier if the at least one protective zone is clear, • Checking whether a protective zone violation occurs after lowering the load carrier, • Generating a protective zone fault if a protective zone violation has occurred.