Low-Lift Truck Fork Positioning via Distance Sensor Feedback
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Solution Overview
Problem
Low-lift industrial trucks often damage pallets or loads due to incorrect positioning during pallet pickup, as operators must visually monitor fork marks, which is challenging and prone to errors, especially when marks are obscured or difficult to discern.
Innovation Solution
A low-lift industrial truck equipped with a load lifting assistance system featuring a distance sensor and processing unit that measures the distance between the load and the truck's front wall, generating a stop signal to prevent collisions and automatically positioning the load fork for safe lifting, using sensors like ultrasonic, laser, or radar, and an acceleration sensor to differentiate between longitudinal and transverse insertions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the operator visually monitors the fork mark during pallet pickup, then the positioning accuracy can be maintained, but the operator's attention is continuously required and errors occur when marks are obscured or difficult to discern
Solution Approach 1:
The patent replaces the manual visual monitoring system with an automated optical detection system. A sensor (optical, ultrasonic, or laser) automatically detects the fork mark position and provides feedback to the control unit, which then guides the fork to the correct position. This eliminates the need for continuous operator attention while maintaining positioning accuracy.
Solution Approach 2:
The system enables the industrial truck to self-position the fork using automated detection and control. The sensor detects the fork mark, the control unit processes the information, and the system automatically adjusts the fork position without requiring operator intervention, making the system serve itself.
2Reliability
If the load fork is inserted deeply into the pallet for longitudinal pickup, then the pallet can be secured, but collisions with the front wall can damage the pallet, load, or truck
Solution Approach 1:
The patent implements a feedback control system where a sensor continuously monitors the position of the load relative to the front wall. When the load reaches a predetermined safe position, the sensor signals the control unit to stop the insertion motion. This feedback mechanism ensures deep insertion for secure pickup while preventing collisions that cause damage.
Solution Approach 2:
The system performs preliminary detection of the load position before complete insertion is achieved. The sensor detects the approaching load and prepares the stop signal in advance, allowing the system to halt insertion at the optimal position before collision occurs, thus preventing damage while maintaining pickup security.
3Reliability
If the industrial truck automatically stops at the predetermined position, then collisions are prevented, but the positioning system complexity increases
Solution Approach 1:
The patent replaces complex mechanical positioning mechanisms with a simpler sensor-based detection system. An optical, ultrasonic, or laser sensor combined with a control unit provides automatic positioning and stop functionality, reducing mechanical complexity while improving reliability through electronic control.
Solution Approach 2:
The control unit serves multiple functions: it processes sensor signals, determines fork mark position, guides fork insertion, and triggers automatic stop. This multi-functionality consolidates what could be separate complex systems into a single integrated control unit, reducing overall system complexity.
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
This solution reduces the risk of damage by automatically guiding the load fork to the correct position, eliminating the need for visual monitoring and ensuring accurate pallet handling, thereby minimizing collisions and damage to pallets, loads, and trucks.
Implementation Method 1
using sensors like ultrasonic, laser, or radar
Implementation Method 2
using sensors like ultrasonic, laser, or radar
Implementation Method 3
using sensors like ultrasonic, laser, or radar
Implementation Method 4
the fork tines of the load fork each comprise at least one load roller in the region of the fork tine tips
Data Source
AI summary
A low-lift industrial truck (2) and a method for operating the same. The industrial truck includes a load fork (4) for picking up a load. Fork tines (6a, 6b) of the load fork (4) each include at least one load roller (8) in a region of fork tine tips (28). The industrial truck also includes a load lifting assistance system having a distance sensor (16) and a processing unit (14). The distance sensor is configured to measure a distance between the load and a front wall (12) of the industrial truck facing the load fork. At least one distance between the load and the front wall is saved in the processing unit and corresponds to a predetermined stop position. The processing unit is configured to process measured values of the distance sensor and to generate a stop signal when a distance corresponding to the stop position (20a, 20b) is determined.