Vehicle Loading Floor Sensor Placement for Safe Load Positioning
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Solution Overview
Problem
Existing loading floor technologies for vehicles lack reliable and safe operation, often resulting in loads being improperly positioned during unloading, leading to potential damage and risk of injury due to operator error.
Innovation Solution
The integration of sensors in the deflection areas to detect loads and control the transport device, combined with a safety edge that functions as a limit switch and damping element, ensures precise positioning and safe handling of loads during loading and unloading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a limit switch is used to stop the load, then the transport device can be controlled, but the operator skill is required to stop the load in a timely manner, leading to potential damage and injury
Solution Approach 1:
The patent replaces the mechanical limit switch system with an optical sensor system. Sensors detect the load's position by sensing its presence in the deflection areas, eliminating the need for operator skill and mechanical switches. This substitution provides automatic, reliable detection and control of the load position.
Solution Approach 2:
The patent implements a feedback control system where sensors continuously monitor the load position and provide signals to the control unit. The control unit automatically adjusts the drive roller to stop the load at the correct position, creating a closed-loop feedback system that ensures reliable operation without operator intervention.
2Reliability
If sensors are arranged in the deflection areas, then the load can be detected reliably and the transport device can be switched off automatically, but the sensors are exposed to external environmental influences
Solution Approach 1:
The patent nests the sensors within the frame structure of the transport device. The sensors are arranged in the deflection areas but are integrated into and protected by the frame, which shields them from external environmental influences while maintaining their detection capability.
Solution Approach 2:
The frame acts as an intermediary structure that protects the sensors from environmental factors. The frame is designed to allow sensor functionality while providing a protective barrier against dust, moisture, and other harmful external influences.
3Object-affected harmful factors
If the safety edge protrudes into the gap area, then the safety function is improved by preventing finger pinching, but the gap area is reduced
Solution Approach 1:
The patent modifies the geometric parameters of the safety edge, making it protrude into the gap area by a controlled amount. This parameter change reduces the gap width to less than the width of an operator's finger, preventing pinching while minimizing the reduction of the overall gap area.
Solution Approach 2:
The safety edge is designed with local quality enhancement in the critical gap area. The protrusion is specifically positioned and dimensioned to provide safety where needed (at the gap) without affecting the overall structure or excessive area reduction.
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
This solution provides reliable and safe operation by ensuring loads are accurately positioned, reducing the risk of damage and injury, while also allowing for efficient use of existing space and minimizing the risk of operator injury from mechanical hazards.
Implementation Method 1
The drive roller is frictionally connected to the conveyor belt, so that when the drive roller is subjected to torque, the load, for example a beverage crate, a shopping container and the like, is moved into a loading position relative to the loading space
Implementation Method 2
The load is detected via the sensors arranged in the deflection areas and the transport device is switched off reliably when the load has reached either the loading position or the unloading position
Implementation Method 3
The safety edge can advantageously fulfill the function of a limit switch on the one hand and a safety function on the other hand. The latter results from the fact that the button protrudes into the gap area in the actuated and unactuated switching position of the sensor
Data Source
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AI summary
The base has a transport device for loading and unloading a loading space (23) of the vehicle, which has a drive roller (9) and guide roller (10), and a rotating conveyor (11) is guided around the guide roller. The axially sensors (46a,46b) are provided for recording the loading and unloading position, and controls the drive roller, where the sensors are arranged in the deflection regions (37a,37b) of the conveyor.