Forklift Rack Stacking Attachment with Lateral Clamp Arms
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Solution Overview
Problem
Existing forklift systems, both manned and unmanned, face challenges in precisely positioning loads, especially when stacking metal racks, due to difficulties in aligning corner posts under varying lighting conditions and the need for costly and time-consuming reprogramming for different rack types.
Innovation Solution
A forklift attachment featuring a rearward and forward carriage structure with upright clamp arms and upper and lower clamps that can move side to side and toward/away from each other, allowing for precise lateral positioning of loads by engaging the exterior sides of the load and lower structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If camera-based systems are used to position the rack over the lower rack, then positioning capability is provided, but reliability deteriorates under low or marginal lighting conditions
Solution Approach 1:
Reflective tape is applied to the corner posts of the rack to serve as an intermediary that actively returns light to the camera. This mediator ensures that the camera receives sufficient light signals even in low-light conditions, thereby maintaining both positioning capability and reliability without requiring additional active light sources or complex illumination systems.
2Measurement precision
If camera-based systems are programmed for a specific type of rack, then positioning accuracy is achieved, but adaptability deteriorates when handling different rack types
Solution Approach 1:
The reflective tape marking system is designed to be universally applicable across different rack types. The camera is programmed to recognize the standardized reflective tape patterns placed on corner posts, allowing the same positioning system to accurately guide placement for various rack configurations without requiring reprogramming, thus achieving both precision and versatility.
3Ease of operation
If manual alignment is used by forklift operator, then flexibility is maintained, but positioning precision deteriorates due to difficulty in seeing corner posts
Solution Approach 1:
Reflective tape with high visual contrast is applied to the corner posts of the rack. This material changes its appearance under different lighting conditions by actively reflecting light back to the operator, making the corner posts highly visible and easy to align with, thereby maintaining operator flexibility while significantly improving positioning precision.
Data Source
AI summary
An attachment for a forklift for positioning a load includes a rearward carriage structure that supports a forward carriage structure to which forwardly extending forks are attached. The forward carriage structure is mounted to move side to side relative to the rearward carriage structure. Upright clamp arms are mounted to the forward carriage structure to move side to side toward and away from each other. Upper clamps are carried by the clamp arms to engage the exterior sides of a load being carried when the clamp arms are moved toward each other. Lower clamps are also carried by the clamp arms at a location below the upper clamps to engage the sides of a load positioned beneath load being carried by the forklift when moved toward each other and simultaneously moving the forward carriage structure to a medial (central) position between the clamp arms.