Material Handling Vehicle Handle Sensing for Continuous Position Feedback
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Solution Overview
Problem
Current material handling vehicle control handles provide only binary information, lacking absolute and continuous position data and angular rate of change, which limits the precision of truck control systems.
Innovation Solution
Implementing a system with two or more sensors, such as accelerometers or gyroscopes, to continuously monitor the position of the control handle and provide angular position and rate of change data to the controller, allowing for adjustments to the lift and drive motors based on this information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If binary sensing (cam-based) is used for handle position detection, then the device complexity is reduced, but the measurement precision and information completeness deteriorate
Solution Approach 1:
The patent replaces the mechanical cam-based binary sensing system with an electronic sensor system (accelerometers and/or gyroscopes) that provides continuous analog measurements of handle position and angular rate, eliminating the need for mechanical cams and switches while dramatically improving measurement precision
Solution Approach 2:
The patent transitions from a static binary state detection system to a dynamic continuous measurement system that captures real-time handle position and angular velocity data, enabling responsive and precise control of the material handling vehicle
2Device complexity
If binary position information is provided, then the device complexity is reduced, but the loss of information increases
Solution Approach 1:
The patent implements a feedback system where sensors continuously measure handle position and angular rate, and this information is fed back to the controller to enable precise control adjustments, ensuring complete information flow from operator input to vehicle response
Solution Approach 2:
The patent changes the measurement parameter from discrete binary states to continuous analog parameters including absolute position, angular velocity, and acceleration, providing comprehensive information about handle position and motion characteristics
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
Enables precise monitoring and adjustment of material handling vehicle operations, improving vehicle performance and operational conditions by providing continuous feedback on handle position and angular changes.
Implementation Method 1
the first sensor is an accelerometer and the second sensor is an accelerometer
Implementation Method 2
one of the first sensor or the second sensor is a gyroscope
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Provided are systems and methods for monitoring the position of a handle (28) of a material handling vehicle (20) comprising a handle, a first sensor (70) positioned along the material handling vehicle, in particular on the mounting block (60) of the handle, a second sensor (72) positioned along the handle, and a controller (26) configured to retrieve first positional information from the first sensor, retrieve second positional information from the second sensor, and compare the first positional information with the second positional information. The controller can adjust the operation of at least one of a lift motor and a drive motor of the material handling vehicle based on the comparison of the first positional information with the second positional information. The sensors are accelerometers or gyroscopes.