Hydraulic Mast Assembly Synchronization for Faster Load Handling
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Solution Overview
Problem
Existing material handling vehicles face inefficiencies in lifting and lowering loads, particularly in terms of speed and safety, especially when encountering obstacles like roofs or doorframes.
Innovation Solution
A method and system for synchronizing the movement of the load carrier and mast elements using hydraulic cylinders, controlled by a control unit, to enhance lifting and lowering speeds while ensuring safety by coordinating hydraulic valve operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the load carrier moves alone to the upper endpoint before the first mast element moves, then the lifting operation is completed in sequence, but the total lifting time is increased and productivity is reduced
Solution Approach 1:
The control unit coordinates hydraulic valves to initiate movement of both the load carrier and first mast element simultaneously before either reaches its endpoint, overlapping their movement phases to reduce total operation time. This preliminary coordinated action eliminates the sequential waiting period where one component must finish before the other begins.
Solution Approach 2:
The system maintains continuous useful action by ensuring that while the load carrier is moving along the first mast element, the first mast element itself is simultaneously moving relative to the second mast element. This continuous overlapping movement maximizes the utilization of hydraulic system capacity and eliminates idle time between operations.
2Object-affected harmful factors
If the first mast element is in its lowest configuration when the load carrier is at a higher position, then the vehicle can move without hitting obstacles, but the lifting operation takes longer to complete
Solution Approach 1:
The control unit performs preliminary coordination by initiating the lowering of the first mast element in advance or simultaneously with the lowering of the load carrier, ensuring that the mast element reaches its lowest position before or as the load carrier approaches its lower endpoint. This preliminary action prevents collision with obstacles while minimizing total operation time.
Solution Approach 2:
The system dynamically adjusts the movement rates of the load carrier and first mast element through coordinated hydraulic valve control. The control unit modulates the speed of each component based on real-time position feedback, allowing the mast element to lower faster when clearance is sufficient and slower when approaching the load carrier's position, thereby preventing collisions while optimizing lifting time.
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
The synchronized movement of load carriers and mast elements increases lifting and lowering efficiency, reduces operation time, and enhances safety by preventing collisions with obstacles.
Implementation Method 1
The first element is movable in relation to the second element to extend or contract the mast assembly. The first mast element comprises a load carrier arranged to be movable along the first mast element from a first lower endpoint to a second upper endpoint. The load carrier is powered by at least one first hydraulic cylinder. The first mast element is powered by at least one second hydraulic cylinder.
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3C
AI summary
Method for operating a lifting and/or lowering movement of a mast assembly (2) comprised in a material handling vehicle (1), wherein a first element (3) of the mast assembly and a load carrier (7 are movable at the same time. There is also disclosed a material handling vehicle (1) comprising, a mast assembly(2), comprising at least a first element (3) and a second element (4), a hydraulic system (30), comprising a first hydraulic cylinder (5) and a second hydraulic cylinder (6), a load carrier (7) arranged movable along a length direction on the first section element (3) from a first lower end point (8) to a second upper endpoint (9), at the same time as the first element is moving.