Telehandler Tool Coupling With Auto-Locking Connector Alignment
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Solution Overview
Problem
The existing coupling systems for work tools in telehandlers are cumbersome and require manual intervention, leading to inefficiencies and potential errors in connecting and disconnecting mechanical, hydraulic, and electrical connections, which can result in contamination and incorrect operations.
Innovation Solution
A coupling device with a tool-holder plate and a coupling plate that uses a locking cylinder and hydraulic/electrical connectors, allowing quick and guided connection/disconnection from a telescopic boom, ensuring correct alignment and protection from dirt, with integrated joystick or radio control for ease of use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual coupling methods are used for mechanical, hydraulic, and electrical connections, then the equipment can be connected to the telehandler, but the coupling process becomes cumbersome and time-consuming
Solution Approach 1:
The patent combines mechanical coupling, hydraulic connection, and electrical connection into a single integrated coupling device. The coupling plate integrates all connection types, allowing simultaneous mechanical engagement, hydraulic hose connection, and electrical plug-in through one unified mechanism, thereby increasing coupling speed while managing complexity through integration rather than separation
Solution Approach 2:
The coupling device is pre-configured with alignment guides, positioning features, and pre-assembled connection components that ensure correct alignment and engagement before the actual coupling operation. The hydraulic hoses and electrical connectors are pre-positioned on the coupling plate, so that when the work tool is brought to the telehandler, all connections are ready for simultaneous engagement without manual assembly steps
2Extent of automation
If manual interlocking is used, then the equipment can be securely connected, but the operator must physically intervene for each connection step
Solution Approach 1:
The coupling device performs self-alignment through integrated positioning features and guides that automatically orient the work tool to the correct position on the telehandler. The system self-positions hydraulic hoses and electrical connectors, and the locking mechanism automatically engages when the coupling plate is brought to the tool-holder plate, eliminating the need for manual intervention in alignment and positioning steps
Solution Approach 2:
The patent replaces manual mechanical interlocking operations with an automated hydraulic actuation system. The hydraulic cylinder automatically extends to engage the locking mechanism, and the control system can automatically initiate the coupling sequence through remote control from the operator's cabin, substituting manual mechanical operations with automated hydraulic and electronic control
3Object-affected harmful factors
If connectors are exposed during coupling, then connections can be made, but the connectors are vulnerable to dirt and contamination
Solution Approach 1:
The coupling plate design nests hydraulic hoses and electrical connectors within a protected structure that shields them from external contamination. The connectors are positioned in recessed areas or protected by the coupling plate itself during the coupling process, and the locking mechanism provides additional protection once engaged, creating multiple layers of protection against dirt and moisture
Solution Approach 2:
The coupling device is designed with protective covers and shielding features that are automatically positioned over connectors during the coupling sequence. The alignment guides and positioning features ensure that connectors are protected from the outset, and the locking mechanism provides continuous protection throughout the operational cycle, preventing contamination before and during connection
4Reliability
If multiple separate connections are made manually, then all connections can be established, but errors and incorrect operations may occur
Solution Approach 1:
The patent merges multiple separate connection operations into a single simultaneous coupling action. The integrated coupling plate allows mechanical engagement, hydraulic connection, and electrical connection to occur at the same time through one unified motion, eliminating the sequential steps that lead to errors and reducing the total time while improving reliability through consistent simultaneous engagement
Solution Approach 2:
The coupling device incorporates positioning sensors and alignment features that provide real-time feedback on the coupling process. The system detects when the work tool is correctly positioned and automatically initiates the coupling sequence only when alignment is confirmed, preventing incorrect operations. The locking mechanism provides feedback when engagement is complete, ensuring all connections are properly established before operation begins
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
Facilitates fast, safe, and intelligent coupling/uncoupling of work tools, reducing the risk of errors and contamination, while maintaining compatibility with various tools and ensuring secure, clean, and correct connections.
Implementation Method 1
a locking cylinder, provided with a seat pad fixed to the tool-holder plate and at least one piston which is extendable with respect to the seat pad along an extension direction
Data Source
AI summary
A coupling device for coupling work tools to a telescopic boom of a telehandler, including a tool-holder plate connectable to the telescopic boom; a coupling plate configured to be fixed to a work tool and releasably retained by the tool-holder plate; a jig including a locking seat fixed to the coupling plate and a locking cylinder, provided with a seat pad fixed to the tool-holder plate and at least one piston, the piston being selectively switchable between a locking position engaged with the locking seat, and an unlocking position which frees the locking seat; a connection device including a first connector rigidly fixed to the coupling plate and a second connector fixed to a connector-holder plate mounted on the piston and alternatively translatable between a connection position, in which each second connector connects to a first connector when the piston is in the locking position, and a disconnection position, in which the second connector disconnects from the first connector when the piston is in the unlocking position.