Operator Presence Detection for Industrial Vehicles
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Solution Overview
Problem
Existing systems fail to effectively detect and enforce the proper standing position of operators in industrial vehicles, which is crucial for safety and compliance with training regulations, as they often require operators to maintain both feet and legs within the operator compartment during use.
Innovation Solution
A multi-detector system comprising a third detector positioned above the threshold plane and first and second detectors positioned to detect an operator's left and right lower extremities separately, ensuring that both detectors cannot be triggered simultaneously, allowing for the enabling, disabling, or limiting of vehicle functions based on the operator's stance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a photoelectric beam system is positioned across the operator compartment entry to detect operator presence, then operator presence can be detected, but the system cannot distinguish between proper and improper standing positions
Solution Approach 1:
The detection system is segmented into multiple independent detector zones: a first detector for the left lower extremity, a second detector for the right lower extremity, and a third detector for the threshold plane. Each detector independently monitors a specific body part, enabling precise detection of operator stance configuration rather than just presence.
Solution Approach 2:
The system transitions from simple presence detection (binary state) to multi-dimensional position verification by detecting the spatial relationship between multiple body parts (left foot, right foot, and threshold). This adds dimensional information about operator stance configuration.
2Measurement precision
If detectors are positioned to detect both lower extremities separately, then proper standing position can be verified, but operators cannot reposition their feet without deactivating the detector
Solution Approach 1:
The detection system dynamically adapts to operator movement within the proper stance configuration. When an operator shifts their feet or repositions within the compartment while maintaining both lower extremities within the compartment boundaries, the system continues to detect proper presence. The detector zones are configured to accommodate natural movement ranges.
Solution Approach 2:
The system monitors changes in detector activation patterns to distinguish between improper exit movements and acceptable repositioning. When an operator properly repositions within the compartment, the detection pattern changes but remains within the valid configuration space. When an operator exits, the detection pattern changes to indicate absence.
3Reliability
If the detection system requires both feet to be detected simultaneously, then training compliance can be enforced, but operator fatigue increases due to rigid positioning requirements
Solution Approach 1:
The system allows dynamic repositioning of feet within the compartment boundaries while maintaining detection compliance. Operators can shift weight, adjust stance width, or move feet within the valid zone without triggering a violation, reducing static posture fatigue while maintaining training compliance.
4Measurement precision
If a third detector is added to detect objects over the threshold plane, then exit detection is improved, but system complexity increases
Solution Approach 1:
The detection system is segmented into functionally distinct zones: two detectors for monitoring lower extremities within the compartment and a third detector for monitoring the threshold plane. This segmentation enables the third detector to specifically catch exit attempts where only one foot leaves the compartment, improving exit detection without requiring a complete detector array.
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 configuration enhances operator safety and training compliance by allowing flexible repositioning without deactivating the presence detector, reducing operator fatigue, and ensuring all body parts remain within the compartment, while enabling or disabling vehicle functions accordingly.
Implementation Method 1
photoelectric operator position detector including a first and second photoelectric beam
Data Source
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AI summary
The present invention relates to an industrial vehicle 5 comprising an operator compartment 10, comprising a floor 90 configured for an operator 15 to stand on, the floor 90 having a front side 42, a left side 40 extending from the front side 42, a right side 45 extending from the front side 42 and opposite the left side 40, and a rear side opposite the front side 42 and extending between the left side 40 and the right side 45; and an operator presence detector 20, the operator presence detector 20 comprising: a first detector 30 located (a) proximate one side of the floor 90 and (b) a distance above the floor 90, wherein a first detection field 80 associated with the first detector 30 extends between the one side of the floor 90 and the side opposite the one side of the floor 90; and a second detector 35 located (a) proximate either (i) the one side of the floor 90 or (ii) proximate the side opposite the one side of the floor 90 and (b) a distance above the floor 90, wherein a second detection field 85 associated with the second detector 35 extends between the one side of the floor 90 and the side opposite the one side of the floor 90; wherein the first detector 30 and the second detector 35 are configured and positioned such that an operator 15 who has both a left lower extremity 60, 62 and a right lower extremity 65, 70 located in the operator compartment 10 cannot cause both the first detector 30 and the second detector 35 to detect an object with a single lower extremity.