Sensorized Bumper Extension for Lift Truck Foot Pinch Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional lift truck foot guards and bumper sensors are not robust enough to prevent operator injury during low-level order-picking operations, as they deteriorate from daily impacts and fail to adequately protect the operator from being overrun or pinned by the truck.
Innovation Solution
An object-sensing bumper extension with both contact and non-contact sensors, such as optical sensors, is implemented to detect potential impacts and trigger a reaction operation, including regenerative braking or reversing, using a durable and flexible material with deformation sensors to prevent operator injury by pushing objects away and filling the gap between the truck and ground.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional foot guards and bumper sensors are used, then the operator is protected to some extent, but the protection is insufficient and the components deteriorate from daily impacts
Solution Approach 1:
The bumper system is segmented into a rigid main bumper and a separate deformable bumper extension made of flexible material. This segmentation allows the extension to absorb impacts through deformation while the main bumper maintains structural integrity, resolving the contradiction between protection reliability and component durability.
Solution Approach 2:
The bumper extension uses material with specific flexibility parameters (Shore 60A rubber or plastic) that allow it to deform under impact forces. This parameter change enables the bumper to provide reliable operator protection through controlled deformation while maintaining overall system durability.
2Reliability
If optical sensors with wide field of view are used, then operator safety is improved, but false triggering increases in non-dangerous situations
Solution Approach 1:
The optical sensor system uses multiple sensors with limited, specific fields of view directed at particular danger zones rather than one wide-field sensor. This local quality approach allows the system to monitor critical areas independently, improving operator safety in danger zones while reducing false triggering from objects in non-dangerous areas.
Solution Approach 2:
The monitoring field is segmented into multiple specific danger zones, each covered by dedicated optical sensors. This segmentation allows the control system to process information from distinct zones independently, reducing false alarms while maintaining comprehensive safety coverage.
3Reliability
If the bumper extension deforms to push objects away, then operator protection is improved, but the gap between truck and ground may allow feet to be pinned
Solution Approach 1:
The deformable bumper extension is pre-configured with downwardly extending features that proactively fill the gap between the truck and ground before impact occurs. This preliminary action prevents operator feet from entering the dangerous pinching zone while maintaining the ability to deform and push objects away during impact.
Solution Approach 2:
The bumper extension combines flexible material (Shore 60A rubber or plastic) with rigid downwardly extending features. This composite structure allows the main body to deform for impact absorption while the extending features maintain gap closure to prevent foot pinching, resolving the contradiction between push-away capability and pinching prevention.
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
The solution significantly reduces the risk of operator injury by reliably detecting encroachment and initiating appropriate truck reactions, such as slowing or reversing, to prevent impacts and ensure safer operation during close proximity maneuvers.
Implementation Method 1
one or more optical sensors can be provided and arranged to provide a field of view of a potential impact zone
Implementation Method 2
one or more contact sensors can be provided that respond to deformation of the object-sensing bumper extension
Data Source
AI summary
An object-sensing bumper extension comprises a durable and flexible material. The bumper extension is connected to the bumper of a vehicle such as a lift truck to detect encroachment and/or impact between the vehicle and an operator or other object. A non-contact sensor detects encroachment of an object within an impact danger zone arranged immediately in front of and near the sides of the vehicle. An impact sensor detects impact between the vehicle and an object. A control system receives sensor signals and initiates a reaction operation of the vehicle in response to sensor activity. The reaction operation can include slowing the vehicle down, stopping the vehicle, and/or reversing the vehicle. The bumper extension can include a plurality of outwardly angled, substantially parallel ridges that deform outwardly and downwardly to push an impacted object away from danger and to fill a gap between the vehicle and the ground.