Pallet Truck Remote Control System for Autonomous Coasting
Solution Overview
Problem
In high-volume warehouses, the efficiency of orderpicking processes is limited by the need for operators to continuously return to the control handle of pallet trucks, wasting time and motion, as existing coast systems require manual activation and deactivation of the deadman brake.
Innovation Solution
A remote control system that allows operators to activate and control the travel command of pallet trucks, enabling coast functions such as constant pressure, time-controlled, and distance-controlled coasting, allowing the vehicle to move without the operator needing to return to the handle, using a wireless control system or voice activation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a deadman brake system is used to automatically stop the vehicle when the operator leaves, then safety is improved, but productivity deteriorates because the operator must continuously return to the control handle
Solution Approach 1:
The patent extracts the brake activation function from the steering arm and relocates it to a separate deadman mechanism. This allows the brake to be controlled independently from the steering operation, enabling the operator to release the steering arm without automatically triggering the brake when coast mode is activated.
Solution Approach 2:
The patent introduces a dynamic coast mode that can be activated or deactivated through a switch or remote control. When activated, the system dynamically changes the brake behavior to allow coasting; when deactivated, the traditional deadman brake behavior is restored. This dynamic adjustment resolves the contradiction between safety and productivity.
2Productivity
If a coast system is activated to allow the vehicle to continue moving when the operator leaves, then productivity is improved, but safety deteriorates because the deadman brake cannot activate
Solution Approach 1:
The patent introduces a coast mode switch or remote control as an intermediary between the operator and the deadman mechanism. This intermediary allows the operator to selectively disable deadman brake activation during coasting operations while maintaining the ability to re-enable it when needed, thus balancing safety and productivity requirements.
Solution Approach 2:
The patent changes the operational parameter of the deadman mechanism by introducing a coast mode that modifies its activation conditions. In coast mode, the deadman mechanism is prevented from activating the brake even when the steering arm is released, whereas in normal mode it functions as intended. This parameter change allows the system to adapt to different operational requirements.
3Reliability
If the operator must continuously return to the control handle to maintain vehicle control, then vehicle safety is maintained, but time is lost and motion is wasted
Solution Approach 1:
The patent extracts the vehicle control function from the operator's continuous presence at the handle by implementing a coast mode that maintains vehicle movement without requiring operator intervention. The vehicle can coast autonomously for a controlled period or distance, eliminating the need for the operator to continuously return to the handle.
Solution Approach 2:
The patent implements preliminary action by having the operator activate the coast mode before leaving the vehicle. Once activated, the coast mode automatically maintains vehicle movement without requiring further operator input, allowing the operator to perform picking tasks without time loss from returning to the vehicle.
4Ease of operation
If remote control activation is implemented to allow coasting from a distance, then operator mobility is improved, but device complexity increases
Solution Approach 1:
The patent introduces a remote control device as an intermediary that allows the operator to activate and control the coast mode from a distance. This remote control communicates with the vehicle's control system to enable or disable coasting without requiring the operator to be physically present at the vehicle, thus improving operator mobility.
Solution Approach 2:
The patent replaces the mechanical requirement of physical presence at the control handle with an electronic or wireless control system. The remote control can be wireless (radio frequency, Bluetooth) or wired, substituting the need for mechanical interaction at the vehicle's control panel with distance-operable controls.
Data Source
AI summary
A control system for controlling motion of a pallet truck vehicle includes three modes of operation for controlling coasting of the vehicle. In a first, constant pressure mode, the vehicle coasts for as long as an activation button is depressed. In a second, time controlled mode, the vehicle coasts for a predetermined period of time. In the third, distance controlled mode, the vehicle coasts for a predetermined distance. Each of these functions can be activated from a remote location using a remote activation device.