Pallet Truck Brake Release Sensor and Tiller Arm Profile

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Solution Overview

Problem

Pallet trucks often experience unintended abrupt stops due to users unintentionally moving the tiller into a lower brake zone, lacking a warning mechanism to prevent such involuntary braking.

Innovation Solution

A brake release mechanism with a sensor and profile feature detectable by the sensor, coupled to the tiller arm, which outputs a signal to release the brake, and a feedback mechanism with a biasing member to increase rotational resistance and alert the operator when approaching the brake zone.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the brake zone is positioned at a lower tiller angle for compactness, then the pallet truck structure is more compact, but the operator may unintentionally enter the brake zone causing abrupt stops

Engineering Contradiction:

Improvetiller arm volumeVSAvoidtiller arm operation

Core Design Contradiction:

Volume of moving objectVSEase of operation

Solution Approach 1:

The patent applies preliminary action by providing advance warning to the operator before the tiller arm enters the brake zone. The sensor detects the approach to the brake zone and activates a visual or audible warning signal, allowing the operator to correct the tiller position before unintended braking occurs. This resolves the contradiction by maintaining the compact lower brake zone position while preventing unintentional operation through early warning.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements feedback by using a sensor to continuously monitor the tiller arm position and providing real-time warning signals to the operator when approaching the brake zone. This closed-loop feedback system allows the operator to adjust the tiller arm position based on the warning signal, preventing unintended braking while maintaining the compact structure with the lower brake zone position.

Inventive Principle:

Principle #23Feedback

2Measurement precision

If a sensor-based brake release mechanism is implemented, then the brake control precision is improved, but the device complexity increases

Engineering Contradiction:

Improvetiller arm position detectionVSAvoidbrake release mechanism complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical brake release mechanisms with a sensor-based detection system. The sensor optically or electronically detects the tiller arm position and triggers brake release accordingly, eliminating the need for complex mechanical linkages and switches. This substitution maintains high measurement precision for tiller arm position detection while reducing overall device complexity by using simpler electronic/optical sensing components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11214471B2Pallet truck with brake release and lower brake zone detection mechanism

Publication Date: 2022.01.04 MITSUBISHI LOGISNEXT AMERICAS INC

AI summary

A pallet truck has a brake release mechanism. The pallet truck has a break release mechanism operably coupled to a brake for stopping rotation of a drive wheel. The brake release mechanism includes a brake release sensor and a profile feature that is detectable by the brake release sensor. The profile feature is fixedly coupled to a pivot shaft of a tiller arm of a tiller, and configured to rotate with the pivot shaft as the tiller arm is pivoted. The brake release sensor is positioned adjacent to the pivot shaft and configured to output a signal that causes the brake to release when the profile feature is detected.