Sensor-Guided Hitch Latch for Misaligned Cart Engagement
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Solution Overview
Problem
Materials handling vehicles, such as tuggers, face challenges in accurately engaging carts due to limited maneuverability, particularly in terms of turning radius, when hitching to carts in warehouse environments.
Innovation Solution
A hitch system with a latch, sensors, and an actuator that automatically positions the latch between open and closed positions based on sensor feedback, ensuring accurate cart engagement and improved maneuverability by guiding the cart hook to engage the latch, even in misaligned conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the materials handling vehicle uses a traditional hitch engagement method, then the structure is simple, but the maneuverability (turning radius) is limited
Solution Approach 1:
The latch system transitions from a static fixed-position latch to a dynamic adjustable-position latch. The actuator mechanism enables the latch to move between multiple positions (retracted, intermediate, extended) to adapt to different engagement scenarios, allowing the vehicle to achieve tighter turning radii while maintaining secure cart engagement.
Solution Approach 2:
The receiving member acts as an intermediary component that guides the cart hook into proper alignment with the latch. This mediator structure compensates for misalignment between the vehicle and cart, enabling accurate engagement even during tight turns where perfect alignment would be difficult to achieve.
2Manufacturing precision
If the latch is fixed in position, then the device complexity is low, but the cart engagement accuracy is poor
Solution Approach 1:
The system incorporates sensors that detect the position of the latch and the presence of the cart hook, providing feedback to the control system. This feedback mechanism enables the actuator to automatically adjust the latch position to achieve accurate engagement, ensuring reliable cart coupling even in misaligned conditions.
Solution Approach 2:
The receiving member is positioned and configured in advance to guide the cart hook toward the latch before actual engagement occurs. This preliminary guiding action ensures that the cart hook is properly aligned with the latch, facilitating accurate and reliable engagement.
3Ease of operation
If the actuator has only two positions (locked/unlocked), then the device complexity is reduced, but the ability to guide cart hook engagement is compromised
Solution Approach 1:
The actuator system incorporates three distinct positions (retracted, intermediate, extended) rather than just two, creating a dynamic system that can adapt to different engagement phases. The intermediate position specifically enables the guiding function where the latch partially engages to steer the cart hook into proper alignment before final locking.
Solution Approach 2:
The intermediate position of the actuator performs a preliminary engagement action where the latch partially contacts the cart hook to guide it into proper alignment. This preliminary guiding action occurs before the final locked position is achieved, ensuring accurate engagement.
Data Source
AI summary
A materials handling vehicle comprising a hitch system, and a drive mechanism. The hitch system comprises a hitch and a hitch controller. The hitch comprises a latch, one or more sensors, an actuator, and a receiving member. The latch is positionable between open and closed positions. The actuator is positionable between retracted, intermediate, and extended positions. The receiving member is configured to lead a cart hook to engage the latch when in the closed position. The one or more sensors are configured to detect a position of the latch and a presence of the cart hook received within the receiving member. The hitch controller is configured to position the actuator in one of the retracted position, the intermediate position, and the extended position, and to position the latch in one of the open position and the closed position in response to signals received from the one or more sensors.