Rotary Encoder Integrated in Forklift Sheave Boss
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Solution Overview
Problem
Conventional forklift systems require external sensors for precise positional feedback, which can be costly and expose sensor components, and often need redundant feedback for safety, lacking a simpler and cost-effective solution for accurate mast height measurement.
Innovation Solution
Integration of a rotary encoder within the lifting tether pulley's mounting boss, featuring a magnetic sensor and rotating magnet, to measure and communicate lift height directly to the vehicle's safety system and computer, eliminating external sensors and providing simultaneous feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If external sensors are mounted on the carrier and mast to measure relative position, then positional feedback can be obtained, but sensor components are exposed and system complexity increases
Solution Approach 1:
The sensor assembly is merged with the actuator by integrating the magnetic sensor into the actuator housing and the magnet onto the actuator rod, eliminating the need for separate external sensor mounting on the carrier and mast. This consolidation reduces device complexity while maintaining measurement precision.
Solution Approach 2:
The sensor components are nested within the actuator structure itself - the magnetic sensor is positioned within the actuator housing and the magnet is attached to the actuator rod, creating a compact integrated assembly that eliminates external sensor mounting requirements.
2Reliability
If redundant sensors are installed for safety system feedback, then safety requirements are met, but system cost and complexity increase
Solution Approach 1:
The integrated sensor assembly provides continuous positional feedback to both the vehicle computer and safety system through a single unified measurement system. The magnetic sensor detects magnet position and transmits this information to multiple systems simultaneously, achieving safety redundancy without requiring multiple separate sensor installations.
Solution Approach 2:
The single integrated sensor assembly serves multiple functions: it provides positional feedback for navigation and control to the vehicle computer, simultaneously provides safety monitoring feedback to the safety system, and eliminates the need for separate redundant sensor installations by being a multi-functional component.
3Loss of information
If multiple sensors are used per component for navigation, control, and safety, then comprehensive feedback is achieved, but system cost becomes prohibitive
Solution Approach 1:
The integrated sensor assembly is designed as a universal component that simultaneously serves navigation, control, and safety functions. By positioning the magnetic sensor and magnet to detect actuator position, the same physical assembly provides positional information to the vehicle computer for navigation/control and to the safety system, eliminating the need for multiple separate sensor systems.
Solution Approach 2:
The patent merges the previously separate sensor systems for navigation/control and safety into a single integrated sensor assembly. This consolidation reduces the total number of sensors required, lowering system cost while maintaining complete positional information coverage for all vehicle functions.
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
This solution provides accurate, cost-effective, and internally integrated positional feedback for forklift mast height, enhancing safety and operational efficiency by eliminating the need for external sensors and redundant systems.
Implementation Method 1
a magnetic sensor; and a cover coupled to the sheave and configured to rotate with the sheave, wherein a back face of the cover defines a magnet holder containing a magnet so that the magnet rotates upon actuation of the sheave
Data Source
AI summary
The present disclosure relates to a rotary encoder utilized in cooperation with existing rotary motion of a vehicle mast configured to raise and lower relative to the ground. In particular, an exemplary embodiment of the present disclosure relates to a rotary encoder integrated within a mounting boss of a sheave of a lifting tether pulley to ascertain and communicate mast height to a user and a safety system of the associated vehicle.