Telescopic Cable Protector for Forklift Mast Length Compensation
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Solution Overview
Problem
Industrial trucks with varying lifting mast lengths require multiple specific electrical connecting cable sets, leading to high production costs, logistical complexity, and reduced flexibility in assembly due to the need for vehicle-specific cable configurations, which are time-consuming and difficult to manage.
Innovation Solution
A telescoping protective device for the connecting cable set, allowing the cable to be stored in a compact loop within a cable store, enabling a single version to accommodate multiple mast lengths by adjusting the length of the protective sections, thus reducing the need for multiple cable sets and minimizing installation space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate connection cable set is provided for each mast length, then the electrical wiring is precisely adapted to each forklift truck model, but manufacturing costs increase and assembly flexibility is reduced
Solution Approach 1:
The patent applies universality by designing a single connection cable set that can be used across multiple forklift truck models with different mast lengths. The cable set includes a retractable cable reel and routing elements that allow the same cable assembly to adapt to various mast configurations, eliminating the need for model-specific cable sets while maintaining precise wiring adaptation.
Solution Approach 2:
The patent applies dynamics through the retractable cable reel mechanism that allows the cable length to be dynamically adjusted during mast movement. The cable can be paid out when the mast is raised and retracted when lowered, providing adaptive length compensation without requiring multiple static cable configurations.
2Adaptability or versatility
If the connection cable set is designed for the longest mast, then all mast lengths can be covered, but the cable must be wound up and secured which is time-consuming and vulnerable to damage
Solution Approach 1:
The retractable cable reel provides dynamic cable management that automatically adjusts cable length based on mast position. The cable is integrated into the mast structure through routing elements that guide it along predetermined paths, eliminating manual winding and securing operations while preventing cable damage through protected routing.
Solution Approach 2:
The patent introduces routing elements as intermediaries between the cable and the mast structure. These routing elements guide the cable along safe paths and prevent direct contact with moving parts, reducing vulnerability to damage while simplifying installation through predetermined routing paths.
3Adaptability or versatility
If an excessive length of connecting cable set is used, then it can be stored in a cable storage unit, but the protective tube requires considerable space and obstructs the operator's view
Solution Approach 1:
The retractable cable reel provides dynamic cable storage that only occupies space when cable is paid out. The reel mechanism allows the cable to be compactly stored when not in use, minimizing the space required compared to static storage solutions, while maintaining the ability to provide excessive length for all mast configurations.
4Adaptability or versatility
If coiled cable is used, then varying lengths can be accommodated, but manufacturing costs increase and complex routing and fastening are required
Solution Approach 1:
The retractable cable reel provides a standardized dynamic mechanism that simplifies manufacturing compared to custom coiled cable solutions. The reel and routing elements can be mass-produced as standard components that work with any cable length requirement, eliminating the need for complex custom routing and fastening for each application.
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3
AI summary
The invention relates to an electrical connection cable set (1) for a forklift truck, wherein the forklift truck has a vehicle body and a lifting mast on which a load-handling device is arranged for raising and lowering, wherein the connection cable set (1) comprises at least one electrical connection cable (2) which is led from the vehicle body to at least one electrical component arranged on the lifting mast or on the load-handling device, wherein the connection cable set (1) has a length compensation (3) for compensating for different lengths of the lifting mast. The connection cable set (1) has a telescopic protective device (4) within which the connection cable (2) is arranged, wherein the protective device (4) comprises a cable storage compartment (5) in which the electrical connection cable (2) is guided and stored in a loop (6).