Industrial Truck Load Carrier Detection Using Spacing Sensors
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Solution Overview
Problem
Industrial trucks face challenges in safely and correctly picking up pallets or pallet cages due to operator error, leading to potential damage to the load or the truck, especially in automated systems where subjective assessment is lacking.
Innovation Solution
The integration of a load carrier detection system on the industrial truck, comprising a spacing distance measurement sensor and monitoring sensors connected to a processing unit, which determines the correct pickup position of the load carrier by transmitting signals and only allowing the truck to release when the load is properly positioned, ensuring safe and correct pickup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated industrial trucks are used to eliminate operator error, then productivity and consistency are improved, but the ability to perform subjective assessment and adjustment is lost
Solution Approach 1:
The patent replaces the operator's subjective visual assessment and manual adjustment mechanisms with automated optical sensors (spacing distance measurement sensors and monitoring sensors) and electronic processing units. The sensors automatically detect load carrier positioning and the processing unit electronically evaluates the data to determine correct pickup position, eliminating the need for human operators while maintaining adaptive assessment capabilities through automated detection and decision-making systems.
2Reliability
If multiple sensors and processing units are added to ensure correct load carrier pickup, then reliability is improved, but device complexity increases
Solution Approach 1:
The detection system is segmented into functionally distinct components: spacing distance measurement sensors that measure the distance between the load carrier and fork back, monitoring sensors that detect the presence and position of the load carrier on the load fork, and a processing unit that evaluates the sensor data. This segmentation allows each component to perform its specific function reliably while the modular structure manages overall system complexity through clear functional separation.
Solution Approach 2:
The processing unit acts as an intermediary between the multiple sensors and the control system. It receives data from both the spacing distance measurement sensors and monitoring sensors, evaluates whether the load carrier is correctly positioned, and only then permits the industrial truck to release the load carrier. This intermediary role simplifies the control logic by centralizing the decision-making process and coordinating the inputs from multiple sensors.
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 ensures that pallets are picked up safely and correctly, preventing damage to the load or truck, and is particularly effective in automated systems by ensuring accurate positioning and release only when the load is correctly secured, enhancing safety and operational efficiency.
Implementation Method 1
at least one spacing distance measurement sensor provided on the load fork that is configured to detect a spacing distance between the load carrier and the fork back
Implementation Method 2
at least one monitoring sensor provided on the load fork that is configured to monitor a predetermined measurement region on the load fork
Data Source
AI summary
An industrial truck (2) and a method for operating the same. The industrial truck includes a load fork (4), a fork back (6) and a plurality of fork arms (8a, 8b), each of which include an arm tip at a free end and an arm root arranged on the fork back. The industrial truck includes a load carrier detection system for a load carrier (20, 30, 40) to be transported, which includes at least one spacing distance measurement sensor (14) provided on the load fork that is configured to detect a spacing distance between the load carrier and the fork back, and one or more monitoring sensors (10, 12) provided on the load fork configured to monitor a predetermined measurement region on the load fork. A processing unit for the sensors is configured to determine a reception of the load carrier picked up by the load fork.