Loading Dock Height Detection System

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Solution Overview

Problem

Load-bearing vehicles often attempt to move objects of varying heights through doorways that are lower than the object's height, leading to potential damage to structures and safety risks due to the driver's unawareness of height restrictions.

Innovation Solution

An accident prevention system for loading dock doorways, comprising a first sensor to detect objects exceeding a predetermined height at a specific location and a second sensor to activate an alert system when the object reaches a second location, generating a humanly-perceivable alert to prevent accidents.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If no height detection system is installed, then the device complexity is low, but the safety and reliability of object transport through doorways deteriorates

Engineering Contradiction:
Improvesafety of object transportVSAvoidcomplexity of height detection system
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The first sensor detects object height before the object reaches the doorway, allowing advance identification of potential height conflicts. This preliminary detection enables the system to prepare appropriate responses before the object approaches the restricted area, improving safety without requiring complex real-time intervention mechanisms at the doorway itself.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The system introduces sensors and alert mechanisms as intermediary components between the object and the doorway structure. These intermediaries detect height violations and communicate warnings to operators, preventing direct contact between excessive objects and the doorway structure, thereby protecting the structure without requiring complex mechanical blocking systems.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Reliability

If a single sensor is used to detect excessive height, then the device complexity is reduced, but the reliability of accident prevention deteriorates due to inability to track object movement progression

Engineering Contradiction:
Improvereliability of accident preventionVSAvoidnumber of sensors
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The detection space is divided into multiple zones with separate sensors: a first sensor positioned earlier in the object's path for initial height detection, and a second sensor positioned closer to the doorway for confirmation. This segmentation allows the system to track object movement progression and provide more reliable accident prevention through multi-stage verification.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The system implements feedback through sequential sensor detection, where the first sensor triggers initial monitoring and the second sensor provides confirmation feedback as the object approaches the doorway. This feedback mechanism enhances reliability by verifying object presence and height violations at multiple stages, ensuring accurate accident prevention without requiring overly complex single-sensor systems.

Inventive Principle:
Principle #23Feedback

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

Prevents accidents by alerting operators of excessive object heights, allowing adjustments to ensure safe passage through doorways, thereby reducing damage to structures and minimizing safety risks.

Implementation Method 1

a first sensor configured to detect an object in a first predetermined location and having a height that is greater than a predetermined height

Methodology Applied
Scientific EffectOptical detection: Photoelectric Effect

Implementation Method 2

a second sensor configured to activate responsive to detection by the first sensor of an object having a height that is greater than the predetermined height, the second sensor also being configured to detect an object in a second predetermined location

Methodology Applied
Scientific EffectOptical detection: Photoelectric Effect

Data Source

PatentUS11945667B2Accident prevention system for a door or passageway
Publication Date: 2024.04.02 TOYOTA MOTOR ENG & MFG NORTH AMERICA INC
  • US11945667B2 patent drawing
  • US11945667B2 patent drawing
  • US11945667B2 patent drawing

AI summary

An accident prevention system for a doorway of a loading dock is provided. The system includes a first sensor configured to detect an object in a first predetermined location and having a height that is greater than a predetermined height. A second sensor is configured to activate responsive to detection by the first sensor of an object having a height that is greater than the predetermined height. The second sensor is also configured to detect an object in a second predetermined location after activation of the second sensor. An alert system is configured to generate a humanly-perceivable alert responsive to detection of the object in the second predetermined location after the activation of the second sensor.