Ultrasonic Clamp Depth Detection for Forklift Load Positioning

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Solution Overview

Problem

Existing material handling equipment, such as forklifts with sliding or pivoting clamps, require manual visual confirmation to ensure clamps are correctly positioned relative to the load, which is labor-intensive and time-consuming.

Innovation Solution

Implementing an ultrasonic sensor system with a controller and display assembly to determine the load's depth relative to the clamp tips, using a four-color LED bar to inform the operator of the correct positioning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual visual confirmation is used to check clamp positioning, then the operator can verify load position, but labor time and operational efficiency are reduced

Engineering Contradiction:

Improveload positioning accuracyVSAvoidtime to verify clamp position

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces the manual visual inspection method with an automated optical detection system. A sensor assembly detects the position of the load relative to the clamp arms, and a controller processes this information to generate visual feedback signals. This substitution eliminates the need for the operator to manually exit the cab and visually confirm clamp positioning, thereby resolving the contradiction between reliable positioning verification and time consumption.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system implements a feedback mechanism where the sensor assembly continuously monitors load position, the controller processes the detected information, and a display assembly provides real-time visual feedback to the operator. This closed-loop feedback system enables the operator to verify clamp positioning accuracy without leaving the cab, resolving the time loss issue while maintaining reliable positioning verification.

Inventive Principle:

Principle #23Feedback

2Measurement precision

If the operator exits the cab to visually confirm clamp position, then accurate positioning can be verified, but productivity is reduced

Engineering Contradiction:

Improveclamp position measurementVSAvoidloading operation efficiency

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The patent replaces manual visual measurement with an automated sensor-based measurement system. The sensor assembly optically detects the relative position between the load and clamp arms, providing precise measurement without requiring operator intervention outside the cab. This maintains measurement precision while eliminating productivity loss.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables self-service measurement where the sensor assembly and controller automatically perform the position detection and evaluation functions. The display assembly presents the measurement results to the operator, who can then make positioning decisions without manually measuring or visually confirming positions, thereby maintaining precision while improving productivity.

Inventive Principle:

Principle #25Self-service

3Ease of operation

If no detection system is used, then the system remains simple, but the operator cannot determine correct load depth without exiting the cab

Engineering Contradiction:

Improveease of position verificationVSAvoiddetection system complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent replaces manual verification operations with an automated detection system consisting of a sensor assembly, controller, and display assembly. While this increases device complexity, it dramatically improves ease of operation by allowing the operator to verify load depth and clamp positioning from within the cab through visual feedback signals, eliminating the need to exit the cab for position verification.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enables operators to accurately position loads without exiting the cab, reducing labor and time waste by providing real-time visual feedback on load depth.

Implementation Method 1

The sensor converts electrical energy to acoustic energy during transmission and then acoustic energy back to electrical energy during receiving

Methodology Applied

Scientific EffectUltrasonic wave propagation: Ultrasound

Implementation Method 2

The sensor converts electrical energy to acoustic energy during transmission and then acoustic energy back to electrical energy during receiving

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Data Source

PatentUS12523679B2Depth detector systems

Publication Date: 2026.01.13 CASCADE CORPORATION

AI summary

Depth detector assemblies for material handling attachments are disclosed. In some embodiments, the depth detector assemblies may include at least one ultrasonic sensor removably attached to the material handling attachment. The depth detector assemblies may additionally include a controller removably attached to the material handling attachment and capable of receiving signals from the at least one ultrasonic sensor. The depth detector assemblies may further include a light display capable of being selectively illuminated by the controller to indicate depth of a load relative to the material handling attachment based on the received signals from the at least one ultrasonic sensor.