Industrial Vehicle Speed Limits Based on Calculated Load
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Solution Overview
Problem
Industrial vehicles, such as forklifts, face challenges in controlling maximum speed effectively while carrying loads, especially under varying conditions like different grades and rolling resistance, without direct measurement of the load, which can lead to unsafe operations.
Innovation Solution
A system and method that determine the torque applied to the traction wheel and acceleration of the vehicle to calculate the load being moved, then control the maximum speed based on this calculated load, considering factors like rolling resistance and path grade, using a processor to execute these calculations and adjust speed limits accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the vehicle speed is increased to improve productivity, then the operation efficiency is improved, but the braking capacity becomes insufficient when carrying heavy loads
Solution Approach 1:
The maximum speed limit is made dynamic rather than fixed. The processor continuously calculates the load being moved and adjusts the maximum speed limit accordingly. When a heavy load is detected, the system automatically reduces the maximum speed limit to ensure adequate braking capacity, while allowing higher speeds when the load is lighter, thus optimizing both productivity and safety
Solution Approach 2:
The system implements a feedback mechanism where the processor monitors vehicle acceleration, torque, and other parameters to calculate the actual load being moved. This calculated load information feeds back to the control system, which then adjusts the maximum speed limit in real-time. This closed-loop control ensures the vehicle operates at optimal speeds for the current load condition, maintaining braking capacity while maximizing productivity
2Reliability
If a fixed maximum speed limit is applied to ensure safety, then the braking capacity is sufficient, but the operation efficiency decreases due to unnecessary speed restrictions
Solution Approach 1:
The system transitions from a static, fixed speed limit approach to a dynamic, adaptive speed limit system. The maximum speed limit changes continuously based on the calculated load, allowing the vehicle to travel at higher speeds when safely permissible and reducing speeds only when necessary for safety, thereby eliminating unnecessary speed restrictions
Solution Approach 2:
The system changes the speed limit parameter dynamically based on load conditions. Instead of maintaining a constant conservative speed limit, the processor adjusts the speed limit parameter in real-time according to the calculated load, torque, and acceleration data, optimizing the balance between safety and efficiency
3Device complexity
If the load is not directly measured, then the device complexity is reduced, but the accuracy of load determination decreases
Solution Approach 1:
The system uses intermediary parameters (acceleration, torque, vehicle speed) that are already available from the vehicle's existing sensors and control systems. The processor calculates the load as an intermediate value derived from these measurements, avoiding the need for direct load sensors while achieving accurate load determination through mathematical relationships
Solution Approach 2:
The system replaces direct mechanical load measurement with a computational approach. Instead of using mechanical load cells or force sensors, the processor uses mathematical calculations based on Newton's second law (F=ma), deriving load information from acceleration measurements and vehicle parameters, thereby substituting a complex mechanical measurement system with a simpler computational system
Data Source
AI summary
Controlling a maximum vehicle speed for an industrial vehicle includes determining, by a processor of the industrial vehicle, a torque applied to the traction wheel of the industrial vehicle; converting the torque to an equivalent force value; and determining an acceleration of the industrial vehicle while the torque is applied to the traction wheel. Additional steps include calculating a load being moved by the industrial vehicle, based at least in part on the acceleration and the equivalent force value; and controlling the maximum speed of the industrial vehicle based on the calculated load being moved by the industrial vehicle.