Forklift Load Detector With Swing-Arm Angle Sensing
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Solution Overview
Problem
Existing load position detectors for forklift trucks lack accuracy in detecting the position of a load on a fork, particularly for unmanned automated operations, necessitating more precise real-time detection.
Innovation Solution
A forklift truck equipped with a load detector comprising a shaft, an arm that swings upon contact with the load, and an angle detection sensor to calculate the distance between the load and an extending portion based on the swing angle, enabling continuous position monitoring and detection of load abnormalities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple limit switch configuration is used to detect load position, then device complexity is reduced, but measurement precision deteriorates
Solution Approach 1:
The patent replaces the mechanical limit switch detection system with an optical angle detection sensor system. The angle detection sensor uses optical principles to detect the swing angle of the arm, providing continuous and precise load position information without the discrete on/off states of mechanical switches. This substitution enables real-time accurate measurement while maintaining system simplicity.
Solution Approach 2:
The patent transitions from static limit switch positions to dynamic angle detection. The angle detection sensor continuously monitors the swing angle of the arm as it contacts the load, enabling real-time detection of load position changes. This dynamic measurement approach provides continuous position information rather than discrete threshold-based detection.
2Productivity
If continuous real-time detection is implemented for automated operation, then productivity is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical limit switch systems with a simpler optical angle detection sensor. This substitution reduces mechanical complexity while enabling continuous real-time detection capabilities necessary for automated unmanned operation. The optical sensor provides continuous feedback without the mechanical wear and discrete state limitations of switch-based systems.
3Ease of manufacture
If discrete threshold-based detection is used, then ease of manufacture is improved, but measurement precision deteriorates
Solution Approach 1:
The patent replaces threshold-based mechanical switch detection with optical angle detection. The angle detection sensor provides continuous analog measurement of the arm's swing angle, eliminating the need for discrete threshold settings and mechanical switch calibrations. This approach maintains ease of manufacture while dramatically improving measurement precision through continuous feedback.
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
Accurately determines the position and posture of the load on the fork, activating alarms for potential falls or inclinations, allowing for continuous unmanned operation and route adjustments without stopping.
Implementation Method 1
an angle detection sensor configured to detect a swing angle of the arm
Data Source
AI summary
A forklift truck includes: a vehicle body; a load handling device; a fork having a load receiving portion for receiving a load and an extending portion extending upward from a proximal end of the load receiving portion; a load detector for detecting the load on the fork; and a controller. The load detector includes: a shaft supported by the fork; an arm configured to come into contact with the load on the fork and swing about the shaft; and an angle detection sensor configured to detect a swing angle of the arm. The controller includes a distance calculation unit. The distance calculation unit is configured to calculate a distance between the load and the extending portion in a longitudinal direction of the load receiving portion based on the swing angle when the load on the fork comes into contact with the arm and the arm swings.