Operator Cage with Covert Load Sensor for Overhead Obstruction Safety
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Solution Overview
Problem
Existing operator cages for machines like mobile elevating work platforms and forklifts do not adequately prevent operator injury from overhead obstructions, as operators may become complacent due to visible safety systems that can be easily overridden, and existing mechanical obstruction sensors are not covert enough to prevent accidents.
Innovation Solution
An operator cage with a covert load sensor system that includes a pivoting control console with resilient biasing means to detect crush loads, a proximity switch for fail-safe operation, and a crush sensor to prevent machine movement when an obstruction is detected, along with a raised rail for protection and easy access, which is designed to be robust and difficult to tamper with.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical obstruction sensor is used to detect crush loads, then operator safety is improved, but the sensor becomes obvious and operators may become complacent or try to override it
Solution Approach 1:
The patent applies the principle of making the safety system covert by changing its visual presence. Instead of using obvious mechanical sensors that operators can see and potentially override, the invention uses load sensors integrated into the console structure that are not immediately apparent to operators, thereby maintaining safety while preventing complacency and tampering
Solution Approach 2:
The patent uses load sensors as an intermediary mechanism to detect crush loads indirectly through the console structure rather than using direct mechanical obstruction sensors. This intermediary approach allows the safety system to function reliably while remaining covert and difficult for operators to override
2Reliability
If a safety switch system is used to interrupt drive movement, then operator protection is improved, but the system can be easily overridden by disconnecting the safety switch or jamming objects
Solution Approach 1:
The patent replaces the mechanical obstruction sensor and manual safety switch system with load sensors that detect crush loads through the console structure. This substitution eliminates the need for operators to manually activate or override safety switches, as the system automatically detects dangerous conditions through load measurements, making it much harder to bypass
3Ease of manufacture
If the control console is made robust as a one-piece unit, then manufacturing simplicity and strength are improved, but the covert nature of the safety system must be maintained
Solution Approach 1:
The patent merges the safety detection function directly into the control console structure by integrating load sensors into the one-piece console unit. This combination allows the console to maintain its robust, simple manufacturing characteristics while simultaneously incorporating the covert safety detection capability, as the sensors are integrated rather than added as separate visible components
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 system effectively reduces operator complacency by being covert and prevents machine movement when crush loads are detected, ensuring operator safety without allowing easy override, thus reducing the risk of injury from overhead obstructions.
Implementation Method 1
a load sensor that is constructed and arranged to sense an external load applied to the console
Implementation Method 2
resilient biasing means that is constructed and arranged to bias the console towards the unloaded condition
Data Source
AI summary
An operator cage (6) for a machine such as a mobile elevating work platform comprises a base unit (22) and a fence assembly (25), a control console (32) and a load sensor (46) that is constructed and arranged to sense an external load applied to the console. The console (32) is mounted for pivoting movement and the load sensor (46) is constructed and arranged to detect movement of the console from an unloaded condition to a loaded condition.