Pallet Position Sensor for Automatic Double-Bite Pickup
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Solution Overview
Problem
The positioning of a pallet on a forklift's forks can be challenging for human operators, leading to potential load shifting, increased risk of tipping, and reduced stability due to improper placement, especially when obstructed views hinder accurate assessment.
Innovation Solution
A pallet position sensor, such as a non-contact distance sensor, is used to determine when nesting against the fork backrest is achieved, triggering a double bite procedure if necessary, ensuring proper pallet placement through automatic repositioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a human operator determines pallet placement, then operational flexibility is maintained, but measurement precision of pallet position is insufficient due to obstructions
Solution Approach 1:
The patent replaces the human operator's visual assessment with an automated optical sensor system (specifically a stereo camera system) to measure pallet position. The sensor system captures images of the pallet and fork backrest, processes these images to determine nesting status, and eliminates the need for manual measurement while overcoming obstructions that limit human view.
Solution Approach 2:
The patent introduces an intermediary processing system between the sensor and the control decision. The system includes image capture devices, image processing units, and control logic that mediates the raw sensor data into actionable pallet position information, enabling accurate measurement even when direct line-of-sight is blocked by forklift components.
2Ease of operation
If pallet is positioned far out on forks, then loading ease is improved, but forklift stability deteriorates due to increased tipping risk
Solution Approach 1:
The patent implements a feedback control system where the sensor continuously monitors pallet position relative to the fork backrest. The system compares the measured position against predefined thresholds and provides feedback to the control system, which automatically adjusts fork extension or pallet positioning to maintain optimal stability while ensuring proper nesting.
Solution Approach 2:
The system performs preliminary measurement and assessment of pallet position before the forklift begins transport operations. By detecting whether the pallet is properly nested against the backrest in advance, the system can prevent unstable configurations from arising during operation, addressing the stability issue before it becomes hazardous.
3Productivity
If single lift operation is used, then productivity is improved, but reliability of pallet placement deteriorates when obstructions prevent proper positioning
Solution Approach 1:
The patent makes the pallet handling process dynamic and adaptable rather than rigid. The sensor system continuously monitors the lifting process and can detect when proper nesting is not achieved due to obstructions. The system then dynamically adjusts the operation by initiating a second lift or repositioning maneuver, ensuring reliability while maintaining high productivity through automated decision-making.
Solution Approach 2:
The system performs preliminary positioning attempts and sensor verification before committing to the final transport operation. By assessing pallet nesting status in advance and during the lifting process, the system can identify placement failures early and correct them through additional positioning operations, ensuring reliable pallet placement without significantly reducing overall handling speed.
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
Enhances safety and reliability by confirming pallet nesting and automatically adjusting placement, reducing the risk of load movement and improving forklift stability during transport.
Implementation Method 1
A pallet position sensor, e.g., a non-contact distance sensor
Data Source
AI summary
A pallet position sensor is used in some embodiments to determine when nesting of a pallet against a fork backrest has been achieved. If nesting has not been achieved following a pallet pickup operation a double bite procedure is automatically implemented in some embodiments in response to the pallet position sensor failing to detect successful pallet nesting on the forks. The use of the pallet position sensor allows for reliable confirmation of nesting of the pallet regardless of whether a normal or double bite pick operation is implemented. By using the output of the sensor to confirm nesting and to trigger a double bite procedure when nesting is not achieved with a single fork placement, e.g., extension operation, safety and reliability is enhanced as compared to systems which do not include a distance sensor capable of sensing the pallet position at the front of the forklift assembly.