Remote-Controlled Forklift Top Mount System
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Solution Overview
Problem
Existing methods for mounting a forklift onto a carrying vehicle require operators to work at elevated heights, posing safety risks and requiring significant skill, as they need to manually position the forklift while it is raised or lowered.
Innovation Solution
A method using a top mount system with a track and carriage, operated by a remote control unit, allows the forklift to be raised and positioned onto the vehicle bed without the operator needing to be at height, utilizing a hydraulic ram to move the carriage along the track and a lifting assembly to adjust the forks, enabling remote operation of the forklift's lifting and drive units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the operator manually positions the forklift while it is raised or lowered, then the forklift can be mounted onto the carrying vehicle, but the operator is exposed to height-related hazards and requires significant skill
Solution Approach 1:
A remote control unit acts as an intermediary device, allowing the operator to control the forklift's lifting and positioning from a safe distance on the ground. The remote control unit transmits control signals to the lifting assembly and drive units, eliminating the need for the operator to be at height while maintaining full control over the mounting process.
Solution Approach 2:
The manual mechanical positioning system is replaced with an automated hydraulic lifting system controlled remotely. The hydraulic ram and lifting assembly automatically raise and lower the forklift based on remote control signals, substituting manual mechanical operations with an automated system that reduces operator exposure to hazards.
2Ease of operation
If the operator manually positions the forklift while it is raised or lowered, then the forklift can be mounted onto the carrying vehicle, but the operator requires significant skill for operation
Solution Approach 1:
The remote control unit serves as an intermediary that simplifies the operation interface. Instead of requiring the operator to manually manipulate complex mechanical controls at height, the remote control unit provides simplified control mechanisms that can be operated from the ground, reducing the skill threshold while maintaining precise control over the mounting process.
3Reliability
If the forklift is raised up onto the bed of the carrying vehicle, then the forklift can be securely mounted, but the operator must work at significant height posing safety risks
Solution Approach 1:
The remote control unit acts as a mediator that enables secure mounting while maintaining operator safety. It transmits control signals to the hydraulic lifting assembly, allowing the forklift to be raised and secured on the carrying vehicle bed without the operator needing to be present at height, thus eliminating safety risks while maintaining mounting reliability.
Solution Approach 2:
The manual mechanical lifting system is replaced with an automated hydraulic system controlled remotely. The hydraulic ram automatically performs the lifting and securing operations based on remote control signals, substituting manual mechanical operations with an automated system that ensures reliable mounting while keeping the operator safe on the ground.
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 method reduces operator exposure to height-related hazards and simplifies the mounting process by allowing remote control of the forklift's positioning, enhancing safety and reducing the skill required for operation.
Implementation Method 1
using a hydraulic ram, mounted on the bed of the carrying vehicle and connected to the carriage, to move the carriage along the track
Implementation Method 2
the lifting assembly having means to raise and lower the forks
Data Source
Figure 1(a)~1(d)
Figure 2(a)~2(d)
Figure 3
AI summary
This invention relates to a top mount method, a top mount system (41) and a combination of forklift truck (1) and carrying vehicle (5) having such a top mount system. The top mount method differs from the known methods in that the forklift truck lifting assembly (11) at least is provided with a remote control unit (33) to permit the operator of the forklift to mount the forklift onto the carrying vehicle (5) from a position remote from the forklift. The top mount system (41) comprises a track (7) having a carriage (9) slidably mounted therein and a ram (49) for moving the carriage relative the track. This obviates the need to use the drive of the forklift under remote operation. Finally, there is provided a combination of a forklift and a carrying vehicle having the top mount system which together provide a useful and safer alternative to the known combinations.