An industrial pallet truck is utilized to lift and transport loads between locations. The operator of the pallet truck may be required to move loads repeatedly on and off of the pallet truck within a very short period of time, and is often required to move specific inventory from various locations in what is termed “picking.” During this practice, it is desirable that the operator can leave the pallet truck and pick a load while the pallet truck continues to move in the direction of the next load. In this way, the lifting and transporting of loads is most efficient. To avoid inadvertent vehicle travel, pallet trucks have a dead-man mechanism that engage a vehicle brake in the event that the operator leaves the pallet truck and releases the control arm. It is not practical for the operator to continue to hold the control arm in a non-braking position as he leaves the pallet truck and moves to the next pick location, therefore it is desirable to have a coast control system which retards, or overrides the dead-man brake mechanism, to allow the pallet truck to coast. The coast control system typically holds the control arm in a fixed or variable position between vertical and horizontal, such that the vehicle brake does not become engaged, and the pallet truck is allowed to coast to a stop in a controlled manner.
Coast control systems are well known in the art, whereby the pallet truck may include a means for holding the control arm in a non-braking position during a picking operation. A problem associated with designs known in the art includes mechanisms which are subject to accelerated breakdown and wear due to environmental conditions. For example, some designs provide for exposed mechanisms which after a period of time may not function correctly in certain environments. These environments may include locations having low temperatures, high humidity or where the air contains high particulate counts. Other designs include complex or hard to access mechanisms which may be difficult to replace or repair.
The present invention addresses these and other problems associated with the prior art.
The present invention provides for an improved apparatus, system and method to control the operability of a motorized vehicle such as an industrial pallet truck.
The foregoing and other objects, features and advantages of the invention will become more readily apparent from the following detailed description of a preferred embodiment of the invention which proceeds with reference to the accompanying drawings.
A detailed description of the invention is now provided, making reference to the accompanying figures.
Pick buttons 108 are provided on either side of the steer control handle 13, which may be used to activate a pick state of a coast control system 109 (
The steer control handle 13 has two symmetrically located pick buttons 108 and two symmetrically located variable throttles 107. When the operator is on the operator platform 5 or is walking alongside of the pallet truck 20, the operator may advantageously activate one of the pick buttons 108 or throttles 107 with the same hand that is holding and controlling the steer control handle 13. The pallet truck 20 may be accelerated by means of a traction motor 110 that may be operated in either the low speed travel mode or the high speed travel mode. In either low speed or high speed travel modes, the traction motor 110 may be actuated by means of one of the throttles 107. The rate of acceleration and maximum travel speeds obtained in the low and high speed travel modes are determined according to the current limiting characteristics of the low and high speed travel circuits, respectively. For example, the low speed travel mode provides for a maximum travel speed of approximately 3.5 miles per hour. Activation of the throttle 107 causes the traction motor 110 to move in the forward or reverse direction in the low speed travel mode depending on the command sent by the throttle 107 to the traction motor 110. In the example pallet truck 20 shown in
With the throttle 107 positioned in the forward or reverse direction, the operator may simultaneously or sequentially press either of the two symmetrically located high speed buttons 4, located on the control panel 12 (
The control panel 12 shown in
An alternate embodiment of the invention provides for the auxiliary pick buttons 208 functioning purely to activate the coast control system 109, and not actuate the traction motor 110 on the initial or any subsequent activation of the auxiliary pick buttons 208. Actuation of the traction motor 110 may be accomplished by activating the pick buttons 108 after the coast control system 109 has first been activated.
The control arm 2 and coast control system 109 are shown in
With the pallet truck 20 in a powered-down state, return spring 31 causes the control arm 2 to remain in a vertical position, thereby activating a vehicle brake switch 101. The return spring 31 is shown as being connected internally to the control arm 2, however it could similarly be attached externally. The return spring 31 retains the control arm 2 in the vertical position in the powered-down and powered-up states unless moved to a non-vertical position by the operator. In one embodiment, with the control arm 2 of the pallet truck 20 in a braking position, the low and high speed travel circuits may not be energized and therefore the traction motor 110 may not be actuated, even after the key switch 100 has been turned on and the pallet truck 20 has been powered-on. In another embodiment a dead-man brake override, or “creep speed” button, may be pressed which allows actuation of the traction motor 110 even when the control arm 2 is in a braking position. Actuation of the traction motor 110 according to the brake override button may be restricted to a reduced maximum travel speed of the pallet truck 20.
With the pallet truck 20 in a powered-on state, and the control arm 2 lowered to a non-braking position, the pallet truck 20 automatically enters the low speed travel mode. In this mode, the operator may operate the pallet truck 20 when riding on, when walking alongside, or walking behind, the pallet truck 20. If the operator releases the control arm 2, the return spring 31 causes the control arm 2 to return to a vertical position and activate the vehicle brake switch 101, thereby causing the pallet truck 20 to stop.
The dead-man brake mechanism functions when the operator ceases to hold the control arm 2 in a non vertical position. In this case, the return spring 31 normally applies a force to move the control arm 2 to a vertical, braking position, which in turn activates the vehicle brake switch 101. However, the return spring 31 force may be overcome by the operator holding the steer control handle 13 in a lowered position.
When the coast control system 109 is activated, the control arm 2 is locked in the position intermediate between pivot ranges Y1 and Y3 shown in
An embodiment of the invention is now described making reference to
By applying an upward force to the steer control arm 2 that is locked in a range Y2, a pressure within the actuation cylinder 32 increases until a predetermined pressure causes the pressure switch 36 to open and actuate the solenoid valve 35. The solenoid valve 35 releases the pressure from the actuation cylinder 32 and allows hydraulic fluid to flow back to the reservoir 37. This hydro-mechanically releases the coast control system 109 and allows the steer control arm 2 to be moved from range Y2 to the Y1 braking position according to the upward force. The brake switch 101 is opened when the steer control arm is in range Y1. As previously disclosed, this upward force may be applied either by the operator or by the return spring 31. The motor controller 105 is disabled when the brake switch 101 is opened.
Similarly, when a downward force is applied to the steer control arm 2 that is locked in a range Y2, a pressure within the actuation cylinder 32 increases until a predetermined pressure causes the pressure switch 36 to open and actuate the solenoid valve 35. The solenoid valve 35 releases the pressure from the actuation cylinder 32 and allows hydraulic fluid to flow back to the reservoir 37. This hydro-mechanically releases the coast control system 109 and allows the steer control arm 2 to be moved from range Y2 to the Y3 braking position according to the downward force. The brake switch 101 is opened when the steer control arm is in range Y3, thereby disabling the motor controller 105. The downward force may be applied by the operator.
The coast control system 109 provides for retaining the control arm 2 in an operator selected position between vertical and horizontal, for example. In an alternative embodiment, a mechanical or pneumatic force may be applied to the actuation cylinder 32 that would function to lock the control arm 2 in a user selected position. For example, a pneumatic force could be directed into the actuation cylinder 32 that would lock the rod 38 in a rigid position. Similarly, a mechanical force such as a gear or locking device could hold the rod 38 rigid with respect to the actuation cylinder 32. Other types of actuating cylinders having rods that are known in the art are claimed herein.
With the pallet truck 20 operating in the low speed travel mode, the operator is able to activate the pick state, or walking state, of the pallet truck 20 by activating a pick button 108. The pick button 108, or other type of switch, may be located anywhere on the truck, including the control arm handle 13, the operator platform 5, or on the support bar 7, for example. With the pick state activated by means of a pick button 108 located on the control arm handle 13, the coast control system 109 of the pallet truck is activated which causes the control arm 2 to remain in a non-braking position. This prevents the vehicle brake switch 101 from being activated. As a result, the pallet truck 20 is allowed to coast to a stop after the traction motor 110 is de-actuated.
Activation of the pick button 108 causes the pallet truck 20 to move in the forward direction, towards the forks 10, up to the maximum allowable travel speed in the low speed travel mode. Activation of the pick button 108 also overrides the return spring 31. The pallet truck 20 continues being accelerated in the forward direction so long as the pick button 108 is being depressed, up to a maximum travel speed. When the operator releases the pick button 108, the pallet truck 20 coasts to a stop regardless of whether or not the operator maintains physical contact with the pallet truck 20 or control arm 2, thereby allowing the operator to walk alongside, or ahead of the pallet truck 20 to pick the next load. While the pallet truck 20 is in the pick state, the operator is able to repeatedly accelerate the pallet truck 20 within the low speed travel range by either reactivating the pick button 108, or by holding open the throttle 107.
The pallet truck 20 remains in the pick state until the vehicle brake switch 101 is activated, the high speed travel button 4 is activated, the battery 111 is disconnected, or the key switch 100 is turned off. The battery 111 may become disconnected from the electrical circuit by physical removal of connecting wiring or if the operator presses an emergency off button (not shown), and in either case the pallet truck 20 is no longer be operating in the pick state. If the operator manually forces the control arm 2 into either a vertical or horizontal position, the vehicle brake switch 101 is activated, the traction motor 108 is de-actuated as the low and high speed travel circuits are open, and the pallet truck 20 is longer operating in the pick state.
In a preferred embodiment, activation of the throttle 107, pick button 108, and the high speed button 4 is not effective with the control arm 2 in a braking position. The braking positions of the control arm 2 is specified by an approximate vertical position V and approximate horizontal position H as shown in
As previously indicated,
With the control arm 2 located in a non-braking position, the operator can activate the pick state by pressing the pick button 108. Pressing the pick button 108 closes the pick switch 103, thereby activating the coast control system 109. This energizes the motor controller 105 and actuates the traction motor 110 in the low speed travel mode as limited to a predetermined rate of travel for the pallet truck 10 according to the low speed travel range. The pick state is de-actuated when the pick button 108 is released and therefore the pick switch 103 is opened. The pallet truck 20 remains in the pick state until one of the following conditions occurs: the vehicle brake switch 101 is activated, the high speed switch 102 is activated, the battery 111 is disconnected, or the key switch 100 is turned off.
With the pick switch 103 closed, and the coast control system 109 activated, the control arm 2 is held in an operator selected position between vertical and horizontal by the coast control system 109 which thereby overrides the return spring 31. Therefore, when the operator releases the pick button 108, the traction motor 110 is de-actuated, however the coast control system 109 continues to override the return spring 31 thus allowing the pallet truck 20 to coast to a stop even when the operator is no longer holding the control arm 2 in a non-braking position. This allows the operator to leave the moving pallet truck 20, and walk alongside or ahead of the pallet truck 20 in order to pick the next load. This is considered the pick state or walking state of the pallet truck 20 operation. Pick state allows for continuous activation of the coast control system 109 and actuation of the traction motor 110 in the low speed travel mode, either by pressing the pick button 108 or engaging the throttle 107.
The operator may activate the high speed travel mode by simultaneously or sequentially engaging the throttle 107 and pressing the high speed button 4, which closes the high speed switch 102. After the throttle 107 is engaged, the high speed switch 102 remains closed until the throttle 107 is placed in neutral, the battery 111 is disconnected, or the key switch 100 is turned off. When the high speed switch 102 is closed, the pick button 108 is disabled, and both the pick switch 103 and the traction switch 104 become open. This results in the de-activation of the coast control system 109 if the pallet truck 20 was in the pick state prior to activation of the high speed travel mode.
Disconnecting the battery 111, opening the key switch 100, or opening the brake switch 101, causes all other switches in the circuit to become open, preventing engagement of the traction motor 110 in any of the travel modes or operating states discussed.
In an embodiment of this invention, a coast control enable button 25 shown in
Coast control enable button 25 can be made to simultaneously actuate the traction motor 110, and provide for subsequent actuation of the traction motor after the coast control system 109 has been activated. In this case, coast control enable button 25 would operate the same in all respects as the pick button 108, other than its location, and as described previously. Alternatively, pressing the coast control enable button 25 could alternate between activating and deactivating the coast control system. If the coast control enable button 25 actuates the traction motor 110, then the traction motor 110 could be actuated upon the first instance of the coast control enable button 25 being pressed, and each successive time the coast control enable button 25 is pressed.
An alternative embodiment provides for a coast control enable button 25 as shown in
The system thus described is furthermore compatible with a “creep speed” function whereby the operator is able to over-ride the braking condition of the pallet truck 20 with the control arm 2 in a vertical position, and cause the pallet truck 2 to move in reduced, or creep, speed. By overriding the braking condition with the control arm in a vertical, or near vertical position, the pallet truck 20 can be made to maneuver in a narrow turning radius or avoid getting stuck. In one embodiment, the creep speed would allow for a maximum vehicle travel speed that is less than the maximum travel speed allowed by the low speed travel mode previously described. One embodiment of this invention provides for the creep speed function to enable the pallet truck 20 to maneuver in small confines at a controlled low rate of travel, when the control arm 2 is located in an approximate vertical position V, for example, or in the pivot range Y1 shown in
In a preferred embodiment, the creep speed function is disabled when the steer arm 2 is located in a horizontal position H or in the pivot range Y3, and instead the vehicle braking system would override the creep speed function and bring the pallet truck 20 to a controlled stop. Disabling the creep speed function in the pivot range Y3 would provide the operator an immediate means of braking the pallet truck 20. Furthermore, operation of the creep speed function with the steer arm 2 in the horizontal, or near horizontal position is not consistent with the goal of maneuvering the pallet truck 20 in a narrow confine at the reduced travel speed. With the steer arm 2 in the pivot range Y3, the turning radius of the pallet truck 20 is greatly increased as compared to the steer arm 2 being in a pivot range Y1, for example. The operator who is carefully maneuvering the pallet truck 20 in a narrow confine, would want to reduce the turning radius in order to avoid hitting obstacles.
A creep speed button may be included in the vicinity of the steer control handle 13, for example, which would engage a creep speed mode of the motor controller 105. The creep speed mode may be engaged upon a single press of the creep speed button, or alternatively be engaged only as long as the button is continually held in a pressed condition. Other types of switches, levers or controls may be used instead of the creep speed button, including being located on different parts of the steer arm 2 or on other locations of the pallet truck 20.
Other components, methods, and systems of the pallet truck 20 that are not described in this patent are understood to operate in a similar manner to other conventional pallet trucks known in the existing art. The system and apparatus described above can use dedicated processor systems, micro controllers, programmable logic devices, or microprocessors that perform some or all of the operations. Some of the operations described above may be implemented in software and other operations may be implemented in hardware.
For the sake of convenience, the operations are described as various interconnected functional blocks or diagrams. This is not necessary, however, and there may be cases where these functional blocks or diagrams are equivalently aggregated into a single logic device, program or operation with unclear boundaries.
Having described and illustrated the principles of the invention in a preferred embodiment thereof, it should be apparent that the invention may be modified in arrangement and detail without departing from such principles. I claim all modifications and variation coming within the spirit and scope of the following claims.
This application claims priority and is a Continuation In Part (CIP) of U.S. patent application Ser. No. 11/109,900 filed on Apr. 19, 2005 and U.S. patent application Ser. No. 11/110,095 also filed on Apr. 19, 2005, all of which are assigned in common to NMHG Oregon, Inc. U.S. patent applications Ser. Nos. 11/109,900 and 11/110,095 are herein incorporated by reference.
Number | Date | Country | |
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Parent | 11109900 | Apr 2005 | US |
Child | 11372638 | Mar 2006 | US |
Parent | 11110095 | Apr 2005 | US |
Child | 11372638 | Mar 2006 | US |