Material Handling Vehicle Charging Position Compensation
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Solution Overview
Problem
Conventional material handling vehicle charging systems require precise alignment, which can be challenging, especially when vehicles are carrying loads or have larger stopping tolerances, limiting their ability to automatically charge without manual intervention and accommodating various vehicle sizes and types.
Innovation Solution
A charging device with a position compensation system that includes a sensing array and actuators to align a charging plate with a collector plate in multiple directions, allowing for greater misalignment tolerance (up to 2 feet) and enabling automatic charging of material handling vehicles carrying loads, using retroreflective sensors and a position controller to adjust the charging plate's position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If precise alignment is required for charging, then charging reliability is improved, but ease of operation deteriorates due to difficulty in alignment especially when vehicles are carrying loads
Solution Approach 1:
The charging system performs self-alignment through the position compensation mechanism. The sensing array detects the relative position between charging plate and collector plate, and the controller automatically adjusts the charging plate position without requiring manual alignment operations, enabling the system to service itself
Solution Approach 2:
The patent replaces manual mechanical alignment operations with an automated sensing and control system. The sensing array (optical/electronic) and position compensation mechanism substitute for manual mechanical positioning, allowing automatic alignment even when vehicles are carrying loads
2Manufacturing precision
If manual intervention is required for alignment, then alignment precision is improved, but productivity deteriorates due to time consumption
Solution Approach 1:
The system automatically performs alignment through the position compensation mechanism controlled by the sensing array, eliminating the need for manual intervention. The controller continuously monitors position and adjusts the charging plate automatically, maintaining precision while improving productivity
Solution Approach 2:
The position compensation mechanism operates continuously during the charging process, maintaining alignment precision throughout the charging duration rather than requiring periodic manual adjustments, thus sustaining both precision and high productivity
3Device complexity
If fixed charging plate position is used, then device complexity is reduced, but adaptability deteriorates due to inability to accommodate various vehicle sizes and types
Solution Approach 1:
The charging plate position is made dynamic through the position compensation mechanism. The charging plate can move in multiple directions (X, Y, Z axes) to adapt to different vehicle positions and sizes, transforming a static fixed-position system into a dynamic adjustable system that maintains simplicity while improving versatility
Solution Approach 2:
The position compensation mechanism provides multi-directional adjustment capability that makes the charging device universal. A single charging device can accommodate various vehicle sizes and types by adjusting the charging plate position, eliminating the need for multiple specialized charging stations
4Ease of operation
If position compensation system is added, then ease of operation is improved through automatic alignment, but device complexity increases
Solution Approach 1:
The position compensation system is segmented into independent functional modules: sensing array for detection, controller for processing, and position compensation mechanism for execution. This modular segmentation manages complexity by dividing the system into manageable, independently controllable components
Solution Approach 2:
The controller serves as an intermediary between the sensing array and the position compensation mechanism. It processes sensor signals and generates control commands, acting as a mediator that simplifies the interaction between detection and actuation subsystems, managing 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
The system allows for efficient and automatic charging of material handling vehicles with greater misalignment tolerance, accommodating various vehicle sizes and loads, enhancing operational efficiency and usability by eliminating the need for precise alignment and manual intervention.
Implementation Method 1
using retroreflective sensors and a position controller to adjust the charging plate's position
Data Source
AI summary
A charging device for charging a battery of a material handling vehicle includes a stand having a stationary portion, a moveable portion that moves relative to the stationary portion, and one or more actuators to move the moveable portion. A charging plate and a sensing array can be supported on the moveable portion. The sensing array detects a position of the charging plate relative to a collector plate of the material handling vehicle. The sensing array includes a first sensor to detect a first position of the charging plate along a first direction and a second sensor to detect a first position of the charging plate along a second direction. Based on signal from the sensing array, a position controller operates the one or more actuators to move the moveable portion to align the charging plate with the collector plate for charging.