Telehandler Load Control for Variable Equipment Configurations

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Solution Overview

Problem

Existing telehandler systems face challenges in maintaining and updating load capacity calculations for varying operating configurations and equipment, leading to inaccurate load determinations and safety issues due to overestimated safety factors, limiting operability.

Innovation Solution

A telehandler system with an electronic control unit that calculates maximum liftable loads by determining position parameters, applying safety factors to account for criticality conditions, and adjusting load capacity based on current equipment, reducing the need for pre-calibrated load charts and enabling versatile operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If discrete load tables are used for different operating configurations, then the system is simple to implement, but it becomes difficult to maintain and update when new equipment is added

Engineering Contradiction:

Improveease of implementationVSAvoidadaptability to new equipment

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent replaces the mechanical/table-based load determination system with a computational system. Instead of using discrete load tables that require manual updates, the system uses a computer program that automatically calculates maximum loads by integrating sensor data, structural parameters, and safety factors. This substitution enables the system to adapt to new equipment through software updates rather than requiring new physical tables.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent transforms the load determination approach from fixed discrete values in tables to continuous parameter-based calculations. The system uses position parameters (arm angle, extension, turret rotation) and structural parameters (equipment mass, center of gravity) to dynamically calculate maximum loads, allowing seamless adaptation to different equipment configurations without requiring pre-defined tables for each scenario.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If interpolation between discrete table values is used, then intermediate operating configurations can be handled, but the maximum load determination becomes inaccurate and safety factors are overestimated

Engineering Contradiction:

Improveoperability in intermediate configurationsVSAvoidaccuracy of maximum load determination

Core Design Contradiction:

Adaptability or versatilityVSMeasurement precision

Solution Approach 1:

The patent replaces the interpolation method with direct computational calculation. Instead of estimating loads by interpolating between discrete table values, the system uses physics-based calculations that integrate the actual position parameters and structural parameters to determine the exact maximum load for any operating configuration, eliminating interpolation errors and providing accurate results throughout the entire operating range.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If multiple pre-calibrated load tables are maintained for different equipment, then accurate load limits are provided for known configurations, but the system complexity increases and updates become difficult

Engineering Contradiction:

Improveaccuracy of load limitsVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent implements a universal load determination system that can handle any equipment configuration through a single computational algorithm. The system accepts equipment-specific parameters (mass, center of gravity, dimensions) as inputs and applies the same physics-based calculation methodology regardless of the equipment type, eliminating the need for multiple specialized load tables and reducing system complexity while maintaining accuracy.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent replaces the complex multi-table system with a unified computational approach. The computer program automatically adapts to different equipment by receiving structural parameters and applying the same fundamental calculation principles, significantly reducing system complexity while maintaining or improving accuracy compared to the discrete table approach.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20260028215A1telehandler

Publication Date: 2026.01.29 DIECI SA

AI summary

A telehandler including at least one base frame, provided with ground support wheels and stabilisers, at least one telescopic lifting arm articulated to said base frame, at least one piece of work equipment supported by the lifting arm, and an electronic control unit configured to determine, by sensors, one or more position parameters indicative of a current operating position of the telehandler from among the possible operating positions of the telehandler, calculate a maximum load that can be lifted by the equipment in the current operating position, and activate a safety procedure, if the equipment in the current operating position is subjected to a load that exceeds the maximum load that can be lifted.