Load Handling Controller With Tilt-Adaptive Safety Thresholds
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Solution Overview
Problem
Existing load handling machines face stability issues due to restrictive safety controls that unnecessarily limit productivity, especially when operating on uneven ground, as they fail to account for the machine's orientation relative to the ground.
Innovation Solution
A controller that adjusts safety thresholds based on the absolute orientation of the load handling apparatus relative to a fixed reference, such as horizontal ground, using sensors like accelerometers or gyroscopes to determine the machine's tilt and orientation, allowing for dynamic adjustment of movement restrictions to maintain stability without hindering productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed threshold level is used for safety control to prevent machine tipping, then machine stability is ensured, but productivity is reduced due to unnecessary movement restrictions on uneven ground
Solution Approach 1:
The patent applies dynamics by transitioning from a fixed threshold safety control system to a dynamic threshold system that adapts to changing ground conditions. The controller continuously adjusts the threshold level based on real-time orientation data from sensors (accelerometers, gyroscopes) to match the actual ground inclination, allowing the safety parameter to vary dynamically rather than remaining static. This resolves the contradiction by enabling stability maintenance through adaptive control while avoiding unnecessary restrictions that would reduce productivity.
Solution Approach 2:
The patent implements parameter changes by modifying the threshold parameter based on detected ground orientation. The system measures the actual ground inclination using orientation sensors and adjusts the threshold level accordingly - increasing the threshold when ground is inclined (allowing more movement) and decreasing it when ground is level (maintaining strict safety). This dynamic parameter adjustment resolves the contradiction between stability and productivity by tailoring the safety parameter to actual operating conditions rather than applying a conservative fixed value in all scenarios.
2Productivity
If the threshold level is lowered to allow more lifting arm movement on uneven ground, then productivity improves, but machine stability is compromised
Solution Approach 1:
The patent implements feedback by continuously monitoring ground orientation through sensors and using this information to adjust the threshold level. The system forms a closed-loop control where orientation data feeds back to the controller, which then modifies the threshold parameter accordingly. This feedback mechanism resolves the contradiction by ensuring that increased movement allowances (higher thresholds) are only granted when ground conditions actually support them, thereby maintaining stability while enabling productivity improvements when appropriate.
3Reliability
If a conservative fixed threshold is used to account for uneven ground, then safety is maintained, but cycle times increase and operational efficiency decreases
Solution Approach 1:
The patent applies dynamics by replacing the static conservative threshold with a dynamic threshold that responds to real-time ground conditions. When the ground is level or nearly level, the threshold remains strict (maintaining safety). When ground inclination is detected, the threshold automatically increases (reducing restrictions). This dynamic adaptation resolves the contradiction by eliminating unnecessary time losses during productive operations on uneven ground while maintaining strict safety controls when needed.
Solution Approach 2:
The patent implements parameter changes by adjusting the threshold parameter based on detected ground orientation angles. The system uses orientation sensors to determine ground inclination and modifies the threshold parameter accordingly - keeping it conservative when ground is level (ensuring safety) and increasing it when ground is inclined (reducing cycle time penalties). This parameter adaptation resolves the contradiction between safety and time loss by making the safety parameter context-dependent rather than universally conservative.
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
Ensures stability across varying ground inclinations while minimizing unnecessary movement restrictions, thereby enhancing the machine's operational efficiency and productivity.
Implementation Method 1
receive a signal representative of the orientation of the load handling apparatus with respect to a reference orientation, wherein the reference orientation is an absolute orientation that is configured to be fixed in space irrespective of the orientation of the machine itself
Data Source
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AI summary
A controller 12 for use with a machine 1 comprising a machine body 2, and a load handling apparatus 6, 7 coupled to the machine body and moveable by a movement actuator 8 with respect to the machine body, wherein the controller is configured to receive a signal representative of the orientation of the load handling apparatus with respect to a reference orientation and a signal representative of a moment of tilt of the machine, wherein the controller is further configured to issue a signal for use by an element of the machine including the movement actuator, which in response to the signal issued by the controller, is configured to restrict or substantially prevent a movement of the load handling apparatus when a value of the signal representative of the moment of tilt reaches a threshold value, the threshold value being dependent on the signal representative of the orientation of the load handling apparatus with respect to the reference orientation.