Materials handling vehicle with a module capable of changing a steerable wheel to control handle position ratio

Information

  • Patent Grant
  • 8172033
  • Patent Number
    8,172,033
  • Date Filed
    Tuesday, January 27, 2009
    15 years ago
  • Date Issued
    Tuesday, May 8, 2012
    12 years ago
Abstract
A materials handling vehicle is provided comprising: a frame comprising an operator's compartment; wheels supported on the frame, at least one of the wheels being a steerable wheel; a steer-by-wire system associated with the steerable wheel to effect angular movement of the steerable wheel about a first axis; and a control apparatus. The steer-by-wire system comprises a control handle capable of being moved by an operator to generate a steer control signal, a selection switch capable of generating one of a first select signal and a second select signal, and a steer motor coupled to the steerable wheel to effect angular movement of the steerable wheel about the first axis. The control apparatus may be coupled to the control handle to receive the steer control signal, coupled to the selection switch to receive the one select signal, and coupled to the steer motor to generate a first drive signal to the steer motor to effect angular movement of the steerable wheel about the first axis. The control apparatus may convert the steer control signal to a corresponding desired angular position for the steerable wheel using one of first and second steerable-wheel-to-control-handle-position ratios, wherein the one ratio is selected based on the one select signal.
Description
FIELD OF THE INVENTION

The present invention relates to a materials handling vehicle having a control module capable of changing a steerable wheel to control handle position ratio.


BACKGROUND OF THE INVENTION

U.S. Pat. No. 6,564,897 discloses a steer-by-wire system for a materials handling vehicle. The vehicle comprises a steering tiller. The tiller, however, is not mechanically coupled to a steered wheel. A motor or an electromagnetic brake is used to provide a counter steering resistive force.


SUMMARY OF THE INVENTION

In accordance with a first aspect of the present invention, a materials handling vehicle is provided comprising: a frame comprising an operator's compartment; wheels supported on the frame, at least one of the wheels being a steerable wheel; a steer-by-wire system associated with the steerable wheel to effect angular movement of the steerable wheel about a first axis; and a control apparatus. The steer-by-wire system comprises a control handle capable of being moved by an operator to generate a steer control signal, a selection switch capable of generating one of a first select signal and a second select signal, and a steer motor coupled to the steerable wheel to effect angular movement of the steerable wheel about the first axis. The control apparatus may be coupled to the control handle to receive the steer control signal, coupled to the selection switch to receive the one select signal, and coupled to the steer motor to generate a first drive signal to the steer motor to effect angular movement of the steerable wheel about the first axis. The control apparatus may convert the steer control signal to a corresponding desired angular position for the steerable wheel using one of first and second steerable-wheel-to-control-handle-position ratios, wherein the one ratio is selected based on the one select signal.


In one embodiment, the selection switch comprises a speed selection switch. The first select signal may comprise a low speed select signal and the second select signal may comprise a high speed select signal.


The control apparatus may select the first ratio when the one select signal is equal to the low speed select signal and the control apparatus may select the second ratio when the one select signal is equal to the high speed select signal, wherein the first ratio may be greater than the second ratio.


The control apparatus may change the one steerable-wheel-to-control handle-position ratio in response to the selection switch changing the one select signal and the vehicle being stopped. Alternatively, the control apparatus may change the one steerable-wheel-to-control handle-position ratio in response to the selection switch changing the one select signal, the control handle being located in a position within a first predefined range, the steerable wheel being located in a position within a second predefined range and an error between a desired angular position of the steerable wheel and a determined actual position of the steerable wheel is equal to or less than a predefined value.


The first and second predefined ranges may be equal to ±3 degrees of a centered position and the predefined value may be equal to 3.


In a further embodiment of the present invention, the selection switch may comprise a maneuverability switch. The first select signal may comprise a low resolution select signal and the second select signal may comprise a high resolution select signal.


The control apparatus may select the first ratio when the one select signal is equal to the low resolution signal and the control apparatus may select the second ratio when the one select signal is equal to the high resolution signal, wherein the first ratio is greater than the second ratio.





BRIEF DESCRIPTION OF THE DRAWINGS


FIG. 1 is a perspective view of a materials handling vehicle in which the present invention is incorporated;



FIG. 1A is an exploded view of a portion of an operator's compartment including a floorboard from the vehicle illustrated in FIG. 1;



FIG. 2 is a schematic block diagram of a control apparatus from the vehicle illustrated in FIG. 1;



FIGS. 3-5 are perspective views of a power unit of the vehicle in FIG. 1 with covers removed from the power unit;



FIG. 6 is a view of a tactile feedback device of the vehicle illustrated in FIG. 1;



FIG. 6A is a view, partially in cross section, of a pin extending down from a control handle base, a spring and a block fixed to a steering column plate;



FIGS. 7 and 8 are perspective views of the control handle of the vehicle illustrated in FIG. 1;



FIG. 9 is a view, partially in section, of the control handle and the tactile feedback device;



FIG. 10 illustrates a first curve C1 used to define a steering motor speed limit based on a current traction motor speed when the vehicle is being operated in a power unit first direction and a second curve C2 used to define a steering motor speed limit based on a current traction motor speed when the vehicle being operated in a forks first direction;



FIG. 11 illustrates a curve C3 plotting a first traction motor speed limit or a second traction motor speed limit as a function of a desired steerable wheel angular position or a calculated actual steerable wheel angular position;



FIG. 11A illustrates a curve CA used to define a third traction motor speed limit based on steerable wheel error;



FIG. 11B illustrates a curve CB used to define a fourth traction motor speed limit based on steer rate;



FIG. 11C illustrates a curve CC used to determine a first acceleration reduction factor RF1 based on a calculated current actual angular position of the steerable wheel;



FIG. 11D illustrates a curve CD used to determine a second acceleration reduction factor RF2 based on a traction speed;



FIG. 12 illustrates a curve C4 used to determine a first tactile feedback device signal value based on traction motor speed;



FIG. 13 illustrates a curve C5 used to determine a second tactile feedback device signal value based on steerable wheel error;



FIG. 14 illustrates in block diagram form steps for determining a tactile feedback device signal setpoint TFDS;



FIG. 15 illustrates a curve C6 plotting a first traction motor speed limit as a function of a control handle angle;



FIG. 16 illustrates a curve C7 used to define a second traction motor speed limit based on steerable wheel error;



FIG. 17 illustrates curves C8PF and C8FF used to determine a first tactile feedback device signal value based on traction motor speed; and



FIG. 18 illustrates a curve C9 used to determine a second tactile feedback device signal value based on steerable wheel error.





DETAILED DESCRIPTION OF THE INVENTION

A materials handling vehicle constructed in accordance with the present invention, comprising a pallet truck 10 in the illustrated embodiment, is shown in FIG. 1. The truck 10 comprises a frame 20 including an operator's compartment 30, a battery compartment 40 for housing a battery 42, a base 52 forming part of a power unit 50 and a pair of load carrying forks 60A and 60B. Each fork 60A, 60B comprises a corresponding load wheel assembly 62A, 62B. When the load wheel assemblies 62A, 62B are pivoted relative to the forks 60A, 60B, the forks 60A, 60B are moved to a raised position. The operator's compartment 30 and the battery compartment 40 move with the forks 60A, 60B relative to the power unit 50.


The operator's compartment 30 is defined by an operator's backrest 32, a side wall 44 of the battery compartment 40 and a floorboard 34. An operator stands on the floorboard 34 when positioned within the operator's compartment 30. In the illustrated embodiment, the floorboard 34 is coupled to a frame base 20A along a first edge portion 34A via bolts 134A, washers 134B, nuts 134C, spacers 134D and flexible grommets 134E, see FIG. 1A. A second edge portion 34B of the floorboard 34, located opposite to the first edge portion 34A, rests upon a pair of springs 135. The floorboard 34 is capable of pivoting about an axis AFB, which axis AFB extends through the first edge portion 34A and the flexible grommets 134E. A proximity sensor 36, see FIGS. 1A and 2, is positioned adjacent to the floorboard 34 for sensing the position of the floorboard 34. When an operator is standing on the floorboard 34, it pivots about the axis AFB and moves towards the proximity sensor 36 such that the floorboard 34 is sensed by the sensor 36. When the operator steps off of the floorboard 34, the floorboard 34 is biased in a direction away from the sensor 36 by the springs 135 such that it is no longer sensed by the sensor 36. Hence, the proximity sensor 36 generates an operator status signal indicating that either an operator is standing on the floorboard 34 in the operator's compartment 30 or no operator is standing on the floorboard 34 in the operator's compartment 30. A change in the operator status signal indicates that an operator has either entered or exited the operator's compartment 30.


The power unit 50 comprises the base 52, a side wall 54 and a steering column 56, see FIGS. 3-8. The base 52, side wall 54 and steering column 56 are fixed together such that the steering column 56 does not rotate or move relative to the side wall 54 or the base 52 in the illustrated embodiment. First and second caster wheels, only the first caster wheel 58 is illustrated in FIG. 1, are coupled to the base 52 on opposing sides 52A and 52B of the base 52.


The power unit 50 further comprises a drive unit 70 mounted to the base 52 so as to be rotatable relative to the base 52 about a first axis A1, see FIGS. 4 and 5. The drive unit 70 comprises a support structure 71 mounted to the base 52 so as to be rotatable relative to the base 52, a traction motor 72 mounted to the support structure 71, and a driven steerable wheel 74 mounted to the support structure 71, see FIGS. 3-5. The steerable wheel 74 is coupled to the traction motor 72 so as to be driven by the traction motor 72 about a second axis A2, see FIG. 1. The steerable wheel 74 also moves together with the traction motor 72 and the support structure 71 about the first axis A1.


An encoder 172, see FIG. 2, is coupled to an output shaft (not shown) of the traction motor 72 to generate signals indicative of the speed and direction of rotation of the traction motor 72.


The truck 10 comprises a steer-by-wire system 80 for effecting angular movement of the steerable wheel 74 about the first axis A1. The steer-by-wire system 80 comprises the control handle 90, a tactile feedback device 100, biasing structure 110, a steer motor 120 and the steerable wheel 74, see FIGS. 3, 4, 6 and 9. The steer-by-wire system 80 does not comprise a mechanical linkage structure directly connecting the control handle 90 to the steerable wheel 74 to effect steering of the wheel 74. The term “control handle” is intended to encompass the control handle 90 illustrated in FIG. 1 and like control handles including steering tillers and steering wheels.


The control handle 90 is capable of being rotated by an operator approximately ±60 degrees from a centered position, wherein the centered position corresponds to the steerable wheel 74 being located in a straight-ahead position. The control handle 90 is coupled to the tactile feedback device 100, which, in turn, is coupled to a plate 56A of the steering column 56 via bolts 101, shown in FIG. 6 but not shown in FIG. 9. The bolts 101 pass through bores in the plate 56A and engage threaded bores in a boss 106, shown in FIG. 9, of the tactile feedback device 100. The tactile feedback device 100 may comprise an electrically controlled brake capable of generating a resistance or counter force that opposes movement of the control handle 90, wherein the force varies based on a magnitude of a tactile feedback device signal, which signal will be discussed below. For example, the electrically controlled brake may comprise one of an electrorheological device, a magnetorheological device, and an electromagnetic device. In the illustrated embodiment, the tactile feedback device 100 comprises a device commercially available from the Lord Corporation under the product designation “RD 2104-01.”


As illustrated in FIG. 9, the control handle 90 is fixedly coupled to a shaft 102 of the tactile feedback device 100 such that the control handle 90 and the shaft 102 rotate together. A magnetically controllable medium (not shown) is provided within the device 100. A magnetic field generating element (not shown) forms part of the device 100 and is capable of generating a variable strength magnetic field that changes with the tactile feedback device signal. The magnetically controllable medium may have a shear strength that changes in proportion to the strength of the magnetic field, and provides a variable resistance or counter force to the shaft 102, which force is transferred by the shaft 102 to the control handle 90. As the variable resistance force generated by the tactile feedback device 100 increases, the control handle 90 becomes more difficult to rotate by an operator.


The tactile feedback device 100 further comprises a control handle position sensor 100A, shown in FIG. 2 but not shown in FIG. 9, which senses the angular position of the control handle 90 within the angular range of approximately ±60 degrees in the illustrated embodiment. The control handle position sensor 100A comprises, in the illustrated embodiment, first and second potentiometers, each of which senses the angular position of the shaft 102. The second potentiometer generates a redundant position signal. Hence, only a single potentiometer is required to sense the angular position of the shaft 102. The angular position of the shaft 102 corresponds to the angular position of the control handle 90. An operator rotates the control handle 90 within the angular range of approximately ±60 degrees in the illustrated embodiment to control movement of the steerable wheel 74, which wheel 74 is capable of rotating approximately ±90 degrees from a centered position in the illustrated embodiment. As the control handle 90 is rotated by the operator, the control handle position sensor 100A senses that rotation, i.e., magnitude and direction, and generates a steer control signal corresponding to a desired angular position of the steerable wheel 74 to a steering control module 220 (also referred to herein as a steering control unit 220).


The biasing structure 110 comprises a coiled spring 112 in the illustrated embodiment, see FIGS. 6, 6A and 9, having first and second ends 112A and 112B. The spring 112 is positioned about the boss 106 of the tactile feedback device 100, see FIG. 9. A pin 92, shown in FIGS. 6 and 6A but not shown in FIG. 9, extends down from a base 94 of the control handle 90 and moves with the control handle 90. When the control handle 90 is located in its centered position, the pin 92 is positioned between and adjacent to the first and second spring ends 112A and 112B, see FIG. 6A. The spring ends 112A and 112B engage and rest against a block 115A fixed to and extending down from the plate 56A of the steering column 56 when the control handle 90 is in its centered position, see FIGS. 6 and 6A. As the control handle 90 is rotated by an operator away from its centered position, the pin 92 engages and pushes against one of the spring ends 112A, 112B, causing that spring end 112A, 112B to move away from the block 115A. In response, that spring end 112A, 112B applies a return force against the pin 92 and, hence, to the control handle 90, in a direction urging the control handle 90 to return to its centered position. When the operator is no longer gripping and turning the control handle 90 and any resistance force generated by the tactile feedback device 100 is less than that of the biasing force applied by the spring 112, the spring 112 causes the control handle 90 to return to its centered position.


The steering column 56 further comprises a cover portion 56B, shown only in FIGS. 7 and 8 and not in FIGS. 6 and 9, which covers the tactile feedback device 100.


The steer motor 120 comprises a drive gear 122 coupled to a steer motor output shaft 123, see FIGS. 3 and 4. The drive unit 70 further comprises a rotatable gear 76 coupled to the support structure 71 such that movement of the rotatable gear 76 effects rotation of the support structure 71, the traction motor 72 and the steerable wheel 74 about the first axis A1, see FIGS. 3-5. A chain 124 extends about the drive gear 122 and the rotatable gear 76 such that rotation of the steer motor output shaft 123 and drive gear 122 causes rotation of the drive unit 70 and corresponding angular movement of the steerable wheel 74.


The vehicle 10 further comprises a control apparatus 200, which, in the illustrated embodiment, comprises a traction control module 210, the steering control module 220 and a display module 230, see FIGS. 2, 3 and 7. Each of the modules 210, 220 and 230 comprises a controller or processor for effecting functions to be discussed below. The functions effected by the modules 210, 220 and 230 may alternatively be performed by a single module, two modules or more than three modules. It is also contemplated that the functions discussed herein performed by one module, e.g., the traction control module 210, may be performed by another module, e.g., the steering control module 220. Further, inputs received by one module, e.g., the steering control module 220, may be shared by that module with the remaining modules or a same input may be separately provided by a sensor or input device to two or more modules. The traction control module 210 is mounted to the side wall 54, the steering control module 220 is mounted to the base 52 and the display module 230 is mounted within the steering column 56.


The control handle 90 further comprises first and second rotatable speed control elements 96A and 96B forming part of a speed control apparatus 96. One or both of the speed control elements 96A, 96B may be gripped and rotated by an operator to control a direction and speed of movement of the vehicle 10, see FIGS. 2, 7 and 8. The first and second speed control elements 96A and 96B are mechanically coupled together such that rotation of one element 96A, 96B effects rotation of the other element 96B, 96A. The speed control elements 96A and 96B are spring biased to a center neutral or home position and coupled to a signal generator SG, which, in turn, is coupled to the traction control module 210. The signal generator SG, for example, a potentiometer, forms part of the speed control apparatus 96 and is capable of generating a speed control signal to the traction control module 210. The speed control signal varies in sign based on the direction of rotation of the speed control elements 96A, 96B, clockwise or counterclockwise from their home positions, and magnitude based on the amount of rotation of the speed control elements 96A, 96B from their home positions. When an operator rotates a control element 96A, 96B in a clockwise direction, as viewed in FIG. 7, a speed control signal is generated to the traction control module 210 corresponding to vehicle movement in a power unit first direction. When the operator rotates a control element 96A, 96B in a counter-clockwise direction, as viewed in FIG. 7, a speed control signal is generated to the traction control module 210 corresponding to vehicle movement in a forks first direction.


The control handle 90 further comprises a speed selection switch 98, see FIGS. 2, 7 and 8, which is capable of being toggled back and forth between a high speed position corresponding to a “high speed” mode and a low speed position corresponding to a “low speed” mode. Based on its position, the speed selection switch 98 generates a speed select signal to the traction control module 210. If the switch 98 is in its low speed position, the traction control module 210 may limit maximum speed of the vehicle 10 to about 3.5 MPH in both a forks first direction and a power unit first direction. If the switch 98 is in its high speed position, the traction control module 210 will allow, unless otherwise limited based on other vehicle conditions, see for example the discussion below regarding FIGS. 11, 11A and 11B, the vehicle to be operated up to a first maximum vehicle speed, e.g., 6.0 MPH, when the vehicle is being operated in a forks first direction and up to a second maximum vehicle speed, e.g., 9.0 MPH, when the vehicle is being operated in a power unit first direction. It is noted that when an operator is operating the vehicle 10 without standing on the floorboard 34, referred to as a “walkie” mode, discussed further below, the traction control module 210 will limit maximum speed of the vehicle to the maximum speed corresponding to the switch low speed position, e.g., about 3.5 MPH, even if the switch 98 is located in its high speed position. It is noted that the speed of the vehicle 10 within a speed range, e.g., 0-3.5 MPH, 0-6.0 MPH and 0-9.0 MPH, corresponding to one of the low speed mode/walkie mode, the high speed mode/first maximum vehicle speed, and the high speed mode/second maximum speed is proportional to the amount of rotation of a speed control element 96A, 96B being rotated.


The steer motor 120 comprises a position sensor 124, see FIG. 2. As the steer motor output shaft 123 and drive gear 122 rotate, the position sensor 124 generates a steer motor position signal to the steering control unit 220, which signal is indicative of an angular position of the steerable wheel 74 and the speed of rotation of the steerable wheel 74 about the first axis A1. The steering control unit 220 calculates from the steer motor position signal a current actual angular position of the steerable wheel 74, and the current speed of rotation of the steerable wheel 74 about the first axis A1. The steering control unit passes the calculated current angular position of the steerable wheel 74 and the current speed of rotation of the steerable wheel 74 to the display module 230.


The steering control unit 220 also receives the steer control signal from the control handle position sensor 100A, which, as noted above, senses the angular position of the control handle 90 within the angular range of approximately ±60 degrees in the illustrated embodiment. The steering control unit 220 passes the steer control signal to the display module 230. Since a current steer control signal corresponds to a current position of the control handle 90 falling within the range of from about ±60 degrees and the steerable wheel 74 is capable of rotating through an angular range of ±90 degrees, the display module 230 converts the current control handle position, as indicated by the steer control signal, to a corresponding desired angular position of the steerable wheel 74 by multiplying the current control handle position by a ratio of equal to or about 90/60 in the illustrated embodiment, e.g., an angular position of the control handle 90 of +60 degrees equals a desired angular position of the steerable wheel 74 of +90 degrees. The display module 230 further determines a steer rate, i.e., change in angular position of the control handle 90 per unit time, using the steer control signal. For example, the display module 230 may compare angular positions of the control handle 90 determined every 32 milliseconds to determine the steer rate.


As noted above, the proximity sensor 36 generates an operator status signal indicating that either an operator is standing on the floorboard 34 in the operator's compartment 30 or no operator is standing on the floorboard 34 in the operator's compartment 30. The proximity sensor 36 is coupled to the traction control module 210 such that the traction control module 210 receives the operator status signal from the proximity sensor 36. The traction control module 210 forwards the operator status signal to the display module 230. If an operator is standing on the floorboard 34 in the operator's compartment 30, as indicated by the operator status signal, the display module 230 will allow movement of the steerable wheel 74 to an angular position falling within a first angular range, which, in the illustrated embodiment, is equal to approximately ±90 degrees. If, however, an operator is NOT standing on the floorboard 34 in the operator's compartment 30, the display module 230 will limit movement of the steerable wheel 74 to an angular position within a second angular range, which, in the illustrated embodiment, is equal to approximately ±15 degrees. It is noted that when an operator is standing on the floorboard 34 in the operator's compartment 30, the vehicle is being operated in a rider mode, such as the high speed or the low speed mode noted above. When an operator is NOT standing on the floorboard 34 in the operator's compartment 30, the vehicle may be operated in the “walkie” mode, where the operator walks alongside the vehicle 10 while gripping and maneuvering the control handle 90 and one of the first and second rotatable speed control elements 96A and 96B. Hence, rotation of the steerable wheel 74 is limited during the walkie mode to an angular position within the second angular range.


Typically, an operator does not request that the control handle 90 be turned to an angular position greater than about ±45 degrees from the centered position when the vehicle 10 is operating in the walkie mode. If a request is made to rotate the control handle 90 to an angular position greater than about ±45 degrees and the vehicle 10 is being operated in the walkie mode, the display module 230 will command the traction control module 210 to cause the vehicle 10 to brake to a stop. If the display module 230 has caused the vehicle 10 to brake to a stop, the display module 230 will allow the traction motor 72 to rotate again to effect movement of the driven steerable wheel 74 after the control handle 90 has been moved to a position within a predefined range such as ±40 degrees and the first and second speed control elements 96A and 96B have been returned to their neutral/home positions.


As noted above, the steering control unit 220 passes the calculated current angular position of the steerable wheel 74 and the current speed of rotation of the steerable wheel 74 to the display module 230. The steering control unit 220 further passes the steer control signal to the display module 230, which module 230 converts the steer control signal to a corresponding requested or desired angular position of the steerable wheel 74. If an operator is standing on the floorboard 34 in the operator's compartment 30, as detected by the proximity sensor 36, the display module 230 forwards the requested angular position for the steerable wheel 74 to the steering control unit 220, which generates a first drive signal to the steer motor 120 causing the steer motor 120 to move the steerable wheel 74 to the requested angular position. If an operator is NOT standing on the floorboard 34 in the operator's compartment 30, as detected by the proximity sensor 36, the display module 230 will determine if the requested angular position for the steerable wheel 74 is within the second angular range, noted above. If so, the display module 230 forwards the requested angular position for the steerable wheel 74 to the steering control unit 220, which generates a first signal to the steer motor 120 causing the steer motor 120 to move the steerable wheel 74 to the requested angular position. If the requested angular position for the steerable wheel 74 is NOT within the second angular range, the display module 230 limits the angular position for the steerable wheel 74 forwarded to the steering control unit 220 to the appropriate extreme or outer limit of the second angular range.


As noted above, the encoder 172 is coupled to the output shaft of the traction motor 72 to generate signals indicative of the speed and direction of rotation of the traction motor 72. The encoder signals are provided to the traction control module 210 which determines the direction and speed of rotation of the traction motor 72 from those signals. The traction control module 210 then forwards traction motor rotation speed and direction information to the display module 230. This information corresponds to the direction and speed of rotation of the steerable wheel 74 about the second axis A2.


The display module 230 may define an upper steering motor speed limit based on a current traction motor speed using linear interpolation between points from a curve, which points may be stored in a lookup table. When the truck 10 is being operated in a power unit first direction, points from a curve, such as curve C1 illustrated in FIG. 10, may be used to define a steering motor speed limit based on a current traction motor speed. When the truck 10 is being operated in a forks first direction, points from a curve, such as curve C2 illustrated in FIG. 10, may be used to define a steering motor speed limit based on a current traction motor speed. In the illustrated embodiment, the steering motor speed upper limit decreases as the speed of the traction motor increases beyond about 2000 RPM, see curves C1 and C2 in FIG. 10. As a result, the steering motor responsiveness is purposefully slowed at higher speeds in order to prevent a “twitchy” or “overly sensitive” steering response as an operator operates the vehicle 10 at those higher speeds. Hence, the drivability of the vehicle 10 is improved at higher speeds. It is noted that the steering motor speed limits in curve C2 for the forks first direction are lower than the steering motor speed limits in curve C1 for the power unit first direction. An appropriate steering motor speed limit based on a current traction motor speed is provided by the display module 230 to the steering control module 210. The steering control module 210 uses the steering motor speed limit when generating the first drive signal to the steer motor 120 so as to maintain the speed of the steer motor 120 at a value equal to or less than the steering motor speed limit until the steerable wheel 74 has been moved to a desired angular position. Instead of storing points from curve C1 or curve C2, an equation or equations corresponding to each of the curves C1 and C2 may be stored and used by the display module 230 to determine a steering motor speed limit based on a current traction motor speed.


As noted above, the steering control unit 220 passes the steer control signal to the display module 230, which module 230 converts the steer control signal to a corresponding desired angular position of the steerable wheel 74. The steering control unit 220 also passes the calculated current actual angular position of the steerable wheel 74 to the display module 230. The display module 230 uses the desired angular position for the steerable wheel 74 to determine a first upper traction motor speed limit using, for example, linear interpolation between points from a curve, such as curve C3, illustrated in FIG. 11, wherein the points may be stored in a lookup table. The display module 230 further uses the calculated actual angular position for the steerable wheel 74 to determine a second upper traction motor speed limit using, for example, linear interpolation between points from the curve C3. Instead of storing points from a curve C3, an equation or equations corresponding to the curve may be stored and used by the display module 230 to determine the first and second traction motor speed limits based on a desired angular position for the steerable wheel and a calculated current angular position of the steerable wheel. As is apparent from FIG. 11, the first/second traction motor speed limit decreases as the desired angular position/calculated angular position for the steerable wheel 74 increases so as to improve the stability of the vehicle 10 during high steerable wheel angle turns.


The display module 230 compares a current desired angular position of the steerable wheel 74 to a current calculated actual position of the steerable wheel 74 to determine a difference between the two equal to a steerable wheel error. Since the control handle position and the steerable wheel position are not locked to one another, steerable wheel error results from a delay between when an operator rotates the control handle 90 to effect a change in the position of the steerable wheel 74 and the time it takes the steer motor 120 to effect corresponding movement of the steerable wheel 74 to move the steerable wheel 74 to the new angular position.


The display module 230 uses the steerable wheel error to determine a third upper traction motor speed limit using, for example, linear interpolation between points from a curve, such as curve CA, illustrated in FIG. 11A, wherein the points may be stored in a lookup table. Instead of storing points from a curve, an equation or equations corresponding to the curve CA may be stored and used by the display module 230 to determine the third traction motor speed limit based on steerable wheel error. As is apparent from FIG. 11A, the third traction motor speed limit generally decreases as the steerable wheel error increases.


The display module 230 uses the steer rate to determine a fourth upper traction motor speed limit using, for example, linear interpolation between points from a curve, such as curve CB, illustrated in FIG. 11B, wherein the points may be stored in a lookup table. Instead of storing points from a curve, an equation or equations corresponding to the curve CB may be stored and used by the display module 230 to determine the fourth traction motor speed limit based on steer rate. As is apparent from FIG. 11B, the fourth traction motor speed limit generally decreases as the steer rate increases.


The display module 230 determines the lowest value from among the first, second, third and fourth traction motor speed limits and forwards the lowest speed limit to the traction control module 210 for use in controlling the speed of the traction motor 72 when generating a second drive signal to the traction motor 72.


The display module 230 may generate a high steerable wheel turn signal to the traction control module 210 when the steer control signal corresponds to a steerable wheel angular position greater than about ±7 degrees from its straight ahead position. When the display module 230 is generating a high steerable wheel turn signal, the vehicle is considered to be in a “special for turn” mode.


In the illustrated embodiment, the traction control module 210 stores a plurality of acceleration values for the traction motor 72. Each acceleration value defines a single, constant rate of acceleration for the traction motor 72 and corresponds to a separate vehicle mode of operation. For example, a single acceleration value may be stored by the traction control module 210 for each of the following vehicle modes of operation: low speed/walkie mode, forks first direction; low speed/walkie mode, power unit first direction; high speed mode, forks first direction; high speed mode, power unit first direction; special for turn mode, forks first direction; and special for turn mode, power unit first direction. The traction control module 210 selects the appropriate acceleration value based on a current vehicle mode of operation and uses that value when generating the second drive signal for the traction motor 72.


The display module 230 determines, in the illustrated embodiment, first, second and third acceleration reduction factors RF1, RF2 and RF3.


As noted above, the steering control unit 220 passes the calculated current actual angular position of the steerable wheel 74 and the current speed of rotation of the steerable wheel 74 to the display module 230. The display module 230 may use the calculated current actual angular position of the steerable wheel 74 to determine the first acceleration reduction factor RF1 using, for example, linear interpolation between points from a curve, such as curve CC, illustrated in FIG. 11C, wherein the points may be stored in a lookup table. Instead of storing points from a curve, an equation or equations corresponding to the curve CC may be stored and used by the display module 230 to determine the first acceleration reduction factor RF1. As is apparent from FIG. 11C, after a steered wheel angle of about 10 degrees, the first acceleration reduction factor RF1 decreases generally linear as the steerable wheel angle increases.


As discussed above, the traction control module 210 forwards traction motor rotation speed and direction information to the display module 230. The display module 230 may use the traction motor speed to determine the second acceleration reduction factor RF2 using, for example, linear interpolation between points from a curve, such as curve CD, illustrated in FIG. 11D, wherein the points may be stored in a lookup table. Instead of storing points from a curve, an equation or equations corresponding to the curve CD may be stored and used by the display module 230 to determine the second acceleration reduction factor RF2. As is apparent from FIG. 11D, the second acceleration reduction factor RF2 generally increases as the traction motor speed increases.


As noted above, an operator may rotate one or both of the first and second speed control elements 96A, 96B causing the signal generator SG to generate a corresponding speed control signal to the traction control module 210. The traction control module 210 forwards the speed control signal to the display module 230. As also noted above, the speed control signal varies in magnitude based on the amount of rotation of the speed control elements 96A, 96B from their home positions. Hence, the speed control signal is indicative of the current position of the speed control elements 96A, 96B. The display module 230 may determined the third acceleration reduction factor RF3 using the speed control signal. For example, the third acceleration reduction factor RF3 may equal a first predefined value, e.g., 10, for all speed control signals corresponding to a position of each speed control element 96A, 96B between a zero or home position and a position corresponding to 80% of its maximum rotated position and may equal a second predefined value, e.g., 128, for all speed control signals corresponding to a position of each speed control element 96A, 96B greater than 80% of its maximum rotated position.


The display module 230 determines which of the first, second and third reduction factors RF1, RF2 and RF3 has the lowest value and provides that reduction factor to the traction control module 210. The traction control module 210 receives the selected reduction factor, which, in the illustrated embodiment, has a value between 0 and 128. The module 210 divides the reduction factor by 128 to determine a modified reduction factor. The modified reduction factor is multiplied by the selected acceleration value to determine an updated selected acceleration value, which is used by the traction control module 210 when generating the second drive signal to the traction motor 72. The reduction factor having the lowest value, prior to being divided by 128, effects the greatest reduction in the acceleration value.


Based on the position of the speed selection switch 98, the operator status signal, whether a high steerable wheel turn signal has been generated by the display module 230, the sign and magnitude of a speed control signal generated by the signal generator SG in response to operation of the first and second rotatable speed control elements 96A and 96B, an acceleration value corresponding to the current vehicle mode of operation, a selected acceleration reduction factor, a current traction motor speed and direction as detected by the encoder 172, and a selected traction motor speed limit, the traction control module 210 generates the second drive signal to the traction motor 72 so as to control the speed, acceleration and direction of rotation of the traction motor 72 and, hence, the speed, acceleration and direction of rotation of the steerable wheel 74 about the second axis A2.


Instead of determining first, second and third reduction factors, selecting a lowest reduction factor, dividing the selected reduction factor by 128 and multiplying the modified reduction factor by a selected acceleration value to determine an updated selected acceleration value, the following steps may be implemented by the display module 230 either alone or in combination with the traction control module 210. Three separate curves are defined for each vehicle mode of operation, which modes of operation are listed above. The first curve defines a first acceleration value that varies based on the calculated current actual angular position of the steerable wheel 74. The second curve defines a second acceleration value that varies based on traction motor speed. The third curve defines a third acceleration value that varies based on the speed control signal from the signal generator SG. The display module and/or the traction control module determines using, for example, linear interpolation between points from each of the first, second and third curves corresponding to the current vehicle mode of operations, wherein the points may be stored in lookup tables, first, second and third acceleration values, selects the lowest acceleration value and uses that value when generating the second drive signal to the traction motor 72.


As noted above, the tactile feedback device 100 is capable of generating a resistance or counter force that opposes movement of the control handle 90, wherein the force varies based on the magnitude of the tactile feedback device signal. In the illustrated embodiment, the display module 230 defines a setpoint TFDS for the tactile feedback device signal, communicates the setpoint TFDS to the steering control module 220 and the steering control module 220 generates a corresponding tactile feedback device signal, e.g., a current measured for example in milliAmperes (mA), to the tactile feedback device 100.


In the illustrated embodiment, the display module 230 defines the tactile feedback device signal setpoint TFDS as follows. The display module 230 constantly queries the traction control module 210 for speed and direction of rotation of the traction motor 72, which information is determined by the traction control module 210 from signals output by the encoder 172, as noted above. Based on the traction motor speed, the display module 230 determines a first tactile feedback device signal value TFD1, see step 302 in FIG. 14, using, for example, linear interpolation between points from a curve, such as curve C4, illustrated in FIG. 12, wherein the points may be stored in a lookup table. Instead of storing points from a curve, an equation or equations corresponding to the curve C4 may be stored and used by the display module 230 to determine the first value TFD1. As can be seen from FIG. 12, the first value TFD1 generally increases with traction motor speed.


As noted above, the display module 230 compares the current desired angular position of the steerable wheel 74 to a current calculated actual position of the steerable wheel 74 to determine a difference between the two equal to a steerable wheel error. Based on the steerable wheel error, the display module 230 determines a second tactile feedback device signal value TFD2, see step 302 in FIG. 14, using, for example, linear interpolation between points from a curve, such as curve C5, illustrated in FIG. 13, wherein the points may be stored in a lookup table. Instead of storing points from a curve, an equation or equations corresponding to the curve C5 may be stored and used by the display module 230 to determine the second value TFD2. As can be seen from FIG. 13, the second value TFD2 generally increases with steerable wheel error.


In the illustrated embodiment, the display module 230 sums the first and second values TFD1 and TFD2 together to determine a combined tactile feedback device signal value TFDC, see step 304 in FIG. 14, and multiplies this value by a reduction factor based on a direction in which the vehicle 10 is moving in order to determine the tactile feedback device signal setpoint TFDS, see step 306 in FIG. 14. If the vehicle 10 is being driven in a forks first direction, the reduction factor may equal 0.5. If the vehicle 10 is being driven in a power unit first direction, the reduction factor may equal 1.0. Generally, an operator has only one hand on the control handle 90 when the vehicle 10 is moving in the forks first direction. Hence, the reduction factor of 0.5 makes it easier for the operator to rotate the control handle 90 when the vehicle 10 is traveling in the forks first direction.


The display module 230 provides the tactile feedback device signal setpoint TFDS to the steering control unit 220, which uses the setpoint TFDS to determine a corresponding tactile feedback device signal for the tactile feedback device 100. Because the tactile feedback device signal is determined in the illustrated embodiment from the first and second values TFD1 and TFD2, which values come from curves C4 and C5 in FIGS. 12 and 13, the tactile feedback device signal increases in magnitude as the traction motor speed and steerable wheel error increase. Hence, as the traction motor speed increases and the steerable wheel error increases, the counter force generated by the tactile feedback device 100 and applied to the control handle 90 increases, thus, making it more difficult for an operator to turn the control handle 90. It is believed to be advantageous to increase the counter force generated by the tactile feedback device 100 as the traction motor speed increases to reduce the likelihood that unintended motion will be imparted to the control handle 90 by an operator as the vehicle 10 travels over bumps or into holes/low spots found in a floor upon which it is driven and enhance operator stability during operation of the vehicle. It is further believed to be advantageous to increase the counter force generated by the tactile feedback device 100 as the steerable wheel error increases so as to provide tactile feedback to the operator related to the magnitude of the steerable wheel error.


In a further embodiment, a pressure transducer 400, shown in dotted line in FIG. 2, is provided as part of a hydraulic system (not shown) coupled to the forks 60A and 60B for elevating the forks 60A and 60B. The pressure transducer 400 generates a signal indicative of the weight of any load on the forks 60A and 60B to the display module 230. Based on the fork load, the display module 230 may determine a third tactile feedback device signal value TFD3 using, for example, linear interpolation between points from a curve (not shown), where the value TFD3 may vary linearly with fork load such that the value TFD3 may increase as the weight on the forks 60A and 60B increases. The display module 230 may sum the first, second and third values TFD1, TFD2 and TFD3 together to determine a combined tactile feedback device signal value TFDC, which may be multiplied by a reduction factor, noted above, based on a direction in which the vehicle 10 is moving in order to determine a tactile feedback device signal setpoint TFDS. The display module 230 provides the tactile feedback device signal setpoint TFDS to the steering control unit 220, which uses the setpoint TFDS to determine a corresponding tactile feedback device signal for the tactile feedback device 100.


As discussed above, the proximity sensor 36 outputs an operator status signal to the traction control module 210, wherein a change in the operator status signal indicates that an operator has either stepped onto or stepped off of the floorboard 34 in the operator's compartment 30. As also noted above, the traction control module 210 provides the operator status signal to the display module 230. The display module 230 monitors the operator status signal and determines whether an operator status signal change corresponds to an operator stepping onto or stepping off of the floorboard 34. An operator stops the vehicle before stepping out of the operator's compartment. When the operator leaves the operator's compartment, if the tactile feedback device signal is at a force generating value, e.g., a non-zero value in the illustrated embodiment, causing the tactile feedback device 100 to generate a counter force to the control handle 90, the display module 230 decreases the tactile feedback device signal setpoint TFDS at a controlled rate, e.g., 900 mA/second, until the tactile feedback device signal setpoint TFDS, and, hence, the tactile feedback device signal, equal zero. By slowly decreasing the tactile feedback device signal setpoint TFDS and, hence, the tactile feedback device signal, at a controlled rate and presuming the control handle 90 is positioned away from its centered position, the biasing structure 110 is permitted to return the control handle 90 back to its centered position, i.e., 0 degrees, without substantially overshooting the centered position after the operator has stepped off the floorboard 34. The tactile feedback device signal setpoint TFDS, and, hence, the tactile feedback device signal, are maintained at a zero value for a predefined period of time, e.g., two seconds. Thereafter, the display module 230 determines an updated tactile feedback device signal setpoint TFDS and provides the updated tactile feedback device signal setpoint TFDS to the steering control unit 220. It is contemplated that the display module 230 may only decrease the tactile feedback device signal setpoint TFDS if, in addition to an operator leaving the operator's compartment and the tactile feedback device signal being at a force generating value, the control handle 90 is positioned away from its centered position. It is further contemplated that the display module 230 may maintain the tactile feedback device signal setpoint TFDS at a zero value until it determines that the control handle 90 has returned to its centered position.


If, while monitoring the operator status signal, the display module 230 determines that an operator status signal change corresponds to an operator stepping onto the floorboard 34, the display module 230 will immediately increase the tactile feedback device signal setpoint TFDS for a predefined period of time, e.g., two seconds, causing a corresponding increase in the tactile feedback device signal. The increase in the tactile feedback signal is sufficient such that the tactile feedback device 100 generates a counter force of sufficient magnitude to the control handle 90 to inhibit an operator from making a quick turn request via the control handle 90 just after the operator has stepping into the operator's compartment 30. After the predefined time period has expired, the display module 230 determines an updated tactile feedback device signal setpoint TFDS and provides the updated tactile feedback device signal setpoint TFDS to the steering control unit 220.


Also in response to determining that an operator has just stepped onto the floorboard 34 and if a steer request is immediately made by an operator via the control handle 90, the display module 230 provides an instruction to the steering control module 220 to operate the steer motor 120 at a first low speed, e.g., 500 RPM and, thereafter, ramp up the steer motor speed, e.g., linearly, to a second higher speed over a predefined period of time, e.g., one second. The second speed is defined by curve C1 or curve C2 in FIG. 10 based on a current traction motor speed. Hence, the first drive signal to the steer motor 120 is varied such that the speed of the steer motor 120, i.e., the rate of speed increase, gradually increases from a low value after the operator enters the operator's compartment in order to avoid a sudden sharp turn maneuver.


It is further contemplated that the steerable wheel may not be driven. Instead, a different wheel forming part of the vehicle would be driven by the traction motor 72. In such an embodiment, the traction control module 210 may generate a second drive signal to the traction motor 72 so as to control the speed, acceleration and direction of rotation of the traction motor 72 and, hence, the speed, acceleration and direction of rotation of the driven wheel based on the position of the speed selection switch 98, the operator status signal, whether a high steerable wheel turn signal has been generated by the display module 230, the sign and magnitude of a speed control signal generated by the signal generator SG in response to operation of the first and second rotatable speed control elements 96A and 96B, an acceleration value corresponding to the current vehicle mode of operation, a selected acceleration reduction factor, a current traction motor speed and direction as detected by the encoder 172, and a selected traction motor speed limit.


It is still further contemplated that a vehicle including a mechanical or hydrostatic steering system may include a traction motor 72 controlled via a traction control module 210 and a display module 230 as set out herein presuming the vehicle includes a control handle position sensor or like sensor for generating signals indicative of an angular position of the control handle and its steer rate and a position sensor or like sensor for generating signals indicative of an angular position of a steerable wheel and a speed of rotation of the steerable wheel about an axis A1.


In accordance with a further embodiment of the present invention, the display module 230 may be modified so as to operate in the following manner.


As noted above, the steering control module 220 passes the steer control signal to the display module 230. The steer control signal corresponds to the angular position of the control handle 90. The display module 230 uses the control handle angular position, as defined by the steer control signal, to determine a first upper traction motor speed limit using, for example, a curve, such as curve C6, illustrated in FIG. 15, wherein points from the curve C6 may be stored in a lookup table. A traction speed limit that does not directly correspond to a point in the table can be determined by linear interpolation or other appropriate estimator. Instead of storing points from a curve C6, an equation or equations corresponding to the curve may be stored and used by the display module 230 to determine the first traction motor speed limit based on an angular position of the control handle 90. As is apparent from FIG. 15, the first traction motor speed limit decreases as the angular position of the control handle 90 increases so as to improve the stability of the vehicle 10 during high steerable wheel angle turns.


As noted above, the display module 230 converts the steer control signal to a corresponding desired angular position of the steerable wheel 74. The steering control module 220 also passes the calculated current actual angular position of the steerable wheel 74 to the display module 230. The display module 230 compares a current desired angular position of the steerable wheel 74 to a current calculated actual position of the steerable wheel 74 to determine a difference between the two equal to a steerable wheel error. Since the control handle position and the steerable wheel position are not locked to one another, steerable wheel error results from a delay between when an operator rotates the control handle 90 to effect a change in the position of the steerable wheel 74 and the time it takes the steer motor 120 to move the steerable wheel 74 to the new angular position.


The display module 230 uses the steerable wheel error to determine a second upper traction motor speed limit using, for example, a curve, such as curve C7, illustrated in FIG. 16, wherein points from the curve C7 may be stored in a lookup table. A traction speed limit that does not directly correspond to a point in the table can be determined by linear interpolation or other appropriate estimator. Instead of storing points from a curve, an equation or equations corresponding to the curve C7 may be stored and used by the display module 230 to determine the second traction motor speed limit based on steerable wheel error. As is apparent from FIG. 16, the second traction motor speed limit decreases in a step-wise manner from a maximum speed, 7.8 MPH in the illustrated embodiment, to a creep speed, 2.3 MPH in the illustrated embodiment, when the steerable wheel error is equal to or greater than a first threshold value, e.g., 25 degrees, so as to give an operator an indication that steerable wheel error is excessive and quick movements of the control handle 90 should be reduced or stopped. The second traction motor speed limit returns to the maximum speed when the steerable wheel error is equal to or less than a second threshold value, e.g., 16 degrees, see FIG. 16, providing hysteresis to prevent potential oscillation between the two speed limits.


The display module 230 determines the lowest value between the first and second traction motor speed limits and forwards the lowest speed limit to the traction control module 210 for use in controlling the speed of the traction motor 72 when generating a second drive signal to the traction motor 72.


As noted above, the tactile feedback device 100 is capable of generating a resistance or counter force that opposes movement of the control handle 90, wherein the force varies based on the magnitude of the tactile feedback device signal. In the illustrated embodiment, the display module 230 defines a setpoint TFDS for the tactile feedback device signal, communicates the setpoint TFDS to the steering control module 220 and the steering control module 220 generates a corresponding tactile feedback device signal, e.g., a current measured for example in milliAmperes (mA), to the tactile feedback device 100.


In the illustrated embodiment, the display module 230 defines the tactile feedback device signal setpoint TFDS as follows. The display module 230 constantly queries the traction control module 210 for speed and direction of rotation of the traction motor 72, which information is determined by the traction control module 210 from signals output by the encoder 172, as noted above. Based on the traction motor speed, the display module 230 determines a first tactile feedback device signal value TFD1, using, for example, a curve, such as a power unit first curve C8PF, which curve is used when the power unit 50 is driven first, or a forks first curve C8FF, which curve is used when the truck 10 is driven in a forks first direction, see FIG. 17, wherein points from the curves C8PF and C8FF may be stored in one or more lookup tables. A signal value for TFD1 that does not directly correspond to a point in a table can be determined by linear interpolation or other appropriate estimator. Instead of storing points from one or more curves, an equation or equations corresponding to the curves C8PF and C8FF may be stored and used by the display module 230 to determine the first value TFD1. As can be seen from FIG. 17, the first value TFD1 generally increases with traction motor speed in both the power unit first curve C8PF and the forks first curve C8FF.


As noted above, the display module 230 compares the current desired angular position of the steerable wheel 74 to a current calculated actual position of the steerable wheel 74 to determine a difference between the two equal to a steerable wheel error. Based on the steerable wheel error, the display module 230 determines a second tactile feedback device signal value TFD2 using, for example, a curve, such as curve C9, illustrated in FIG. 18, wherein points from the curve C9 may be stored in a lookup table. A signal value for TFD2 that does not directly correspond to a point in a table can be determined by linear interpolation or other appropriate estimator. Instead of storing points from a curve, an equation or equations corresponding to the curve C9 may be stored and used by the display module 230 to determine the second value TFD2. As can be seen from FIG. 18, the second value TFD2 increases in a step-wise manner from a low value, e.g., 0 mA, to a high value, e.g., 500 mA, when with steerable wheel error is equal to or greater than a first threshold value, e.g., 25 degrees. The second value TFD2 returns to the low value, e.g., 0 mA, when the steerable wheel error is equal to or less than a second threshold value, e.g., 16 degrees.


In the illustrated embodiment, the display module 230 sums the first and second values TFD1 and TFD2 together to determine a combined tactile feedback device signal value TFDC and multiplies this value by a reduction factor based on a direction in which the vehicle 10 is moving in order to determine the tactile feedback device signal setpoint TFDS. If the vehicle 10 is being driven in the forks first direction, the reduction factor may equal 0.5. If the vehicle 10 is being driven in the power unit first direction, the reduction factor may equal 1.0. Generally, an operator has only one hand on the control handle 90 with the other hand positioned on the backrest 32 when the vehicle 10 is moving in the forks first direction. Hence, the reduction factor of 0.5 makes it easier for the operator to rotate the control handle 90 when the vehicle 10 is traveling in the forks first direction. It is contemplated that the tactile feedback device signal value TFDC may be based solely on the second value TFD2.


The display module 230 provides the tactile feedback device signal setpoint TFDS to the steering control module 220, which uses the setpoint TFDS to determine a corresponding tactile feedback device signal for the tactile feedback device 100. Because the tactile feedback device signal is determined in the illustrated embodiment from the first and second values TFD1 and TFD2, which values come from curves C8PF or C8FF and C9 in FIGS. 17 and 18, the tactile feedback device signal increases in magnitude as the traction motor speed and steerable wheel error increase. Hence, as the traction motor speed increases and the steerable wheel error increases, the counter force generated by the tactile feedback device 100 and applied to the control handle 90 increases, thus, making it more difficult for an operator to turn the control handle 90. It is believed to be advantageous to increase the counter force generated by the tactile feedback device 100 as the traction motor speed increases to reduce the likelihood that unintended motion will be imparted to the control handle 90 by an operator as the vehicle 10 travels over bumps or into holes/low spots found in a floor upon which it is driven and enhance operator stability during operation of the vehicle. It is further believed to be advantageous to quickly and significantly increase the counter force generated by the tactile feedback device 100 when the steerable wheel error increases beyond a first threshold value so as to provide tactile feedback to the operator when the steerable wheel error is equal to or greater than the first threshold value.


In accordance with a further embodiment of the present invention, the display module 230 may be modified so as to operate in the following manner.


As noted above, the control handle position sensor 100A, shown in FIG. 2 but not shown in FIG. 9, senses the angular position of the control handle 90 within the angular range of approximately ±60 degrees in the illustrated embodiment. As also noted above, as the control handle 90 is rotated by the operator, the control handle position sensor 100A senses that rotation, i.e., magnitude and direction, and generates a steer control signal to the steering control module 220. The steering control unit 220 passes the steer control signal to the display module 230.


As further noted above, the steer motor position sensor 124 generates a signal to the steering control unit 220, which signal is indicative of an angular position of the steerable wheel 74 and the speed of rotation of the steerable wheel 74 about the first axis A1. The steering control unit 220 calculates from the steer motor position signal a current actual angular position of the steerable wheel 74, and the current speed of rotation of the steerable wheel 74 about the first axis A1 and passes that information to the display module 230. As discussed above, the steerable wheel 74 is capable of rotating approximately ±90 degrees from a centered position in the illustrated embodiment.


As still further noted above, the control handle 90 comprises a speed selection switch 98, see FIGS. 2, 7 and 8, which is capable of being toggled back and forth between a high speed position corresponding to a “high speed” mode and a low speed position corresponding to a “low speed” mode. Based on its position, the speed selection switch 98 generates either a high speed select signal or low speed select signal to the traction control module 210. The traction control module 210 provides the speed select signal to the display module 230. If the switch 98 is in its low speed position, the traction control module 210 may limit maximum speed of the vehicle 10 to about 3.5 MPH in both a forks first direction and a power unit first direction. If the switch 98 is in its high speed position, the traction control module 210 will allow, unless otherwise limited based on other vehicle conditions, see for example the discussion above regarding FIGS. 11, 11A and 11B, the vehicle to be operated up to a first maximum vehicle speed, e.g., 6.0 MPH, when the vehicle is being operated in a forks first direction and up to a second maximum vehicle speed, e.g., 9.0 MPH, when the vehicle is being operated in a power unit first direction.


In this embodiment, the display module 230 converts the current control handle position, as indicated by the steer control signal, to a corresponding desired angular position of the steerable wheel 74 using a steerable-wheel-to-control-handle-position ratio, which ratio is determined based on the position of the speed selection switch 98.


As discussed above, if an operator is standing on the floorboard 34 in the operator's compartment 30, as detected by the proximity sensor 36, the display module 230 forwards the desired angular position for the steerable wheel 74 to the steering control unit 220, which generates a first drive signal to the steer motor 120 causing the steer motor 120 to move the steerable wheel 74 to the requested angular position. If an operator is NOT standing on the floorboard 34 in the operator's compartment 30, as detected by the proximity sensor 36, the display module 230 will determine if the requested angular position for the steerable wheel 74 is within the second angular range, noted above. If so, the display module 230 forwards the requested angular position for the steerable wheel 74 to the steering control unit 220, which generates a first signal to the steer motor 120 causing the steer motor 120 to move the steerable wheel 74 to the requested angular position. If the requested angular position for the steerable wheel 74 is NOT within the second angular range, the display module 230 limits the angular position for the steerable wheel 74 forwarded to the steering control unit 220 to the appropriate extreme or outer limit of the second angular range.


When the speed selection switch 98 is located in the “low speed” mode, the display module 230 multiplies the current control handle position by a ratio equal to 90/60 or 1.5/1.0 in the illustrated embodiment to determine the desired angular position of the steerable wheel 74. For example, if the angular position of the control handle 90 is +60 degrees, the display module 230 multiplies +60 degrees by the ratio of 1.5/1.0 to determine a desired angular position of the steerable wheel 74 equal to +90 degrees. When in the low speed mode, steering is believed to be enhanced when the ratio is equal to 1.5/1.0 because the truck is more maneuverable.


When the speed selection switch 98 is located in the “high speed” mode, the display module 230 multiplies the current control handle position by a ratio equal to 60/60 or 1.0/1.0 in the illustrated embodiment to determine the desired angular position of the steerable wheel 74. For example, if the angular position of the control handle 90 is +60 degrees, the display module 230 multiplies +60 degrees by the ratio of 1.0/1.0 to determine a desired angular position of the steerable wheel 74 equal to +60 degrees. When in the high speed mode and the ratio is equal to 1.0/1.0, the control handle 90 always points in the same direction as the desired angular position of the steerable wheel and the operator is provided with more steering resolution.


An operator may toggle the speed selection switch 98 while the vehicle is moving. In a first embodiment, however, the display module 230 will not change the steerable-wheel-to-control-handle-position ratio from 1.5/1.0 to 1.0/1.0 or from 1.0/1.0 to 1.5/1.0 while the truck 10 is moving. That is, the truck 10 must come to a complete stop before the display module 230 makes a change in the steerable-wheel-to-control-handle-position ratio in response to the switch 98 being toggled, i.e., changed, during truck movement. It is desirable for the truck 10 to come to a complete stop to avoid a rapid change in steerable wheel position if the truck is being steered in a direction away from a straight ahead direction. Such a change in steerable wheel position may occur without any change in the angular position of the control handle 90.


As also noted above, the display module 230 compares a current desired angular position of the steerable wheel 74 to a current calculated actual position of the steerable wheel 74 to determine a difference between the two equal to a steerable wheel error.


In accordance with a further embodiment of the present invention, the display module 230 changes the steerable-wheel-to-control-handle-position ratio from 1.5/1.0 to 1.0/1.0 or from 1.0/1.0 to 1.5/1.0 while the truck 10 is moving in response to the switch 98 being changed if the following conditions are met: the control handle 90 is located in a position within the range of ±3 degrees of its centered or straight ahead position as sensed by the control handle position sensor 100A; the steerable wheel 74 is located within the range of ±3 degrees of its centered or straight ahead position as calculated by the steering control unit 220 from the steer motor position sensor signal; and the magnitude of the steerable wheel error is equal to 3 degrees or less. It is contemplated that the control handle position range may comprise a range less than or slightly greater than ±3 degrees of its centered position; the steerable wheel position range may comprise a range less than or slightly greater than ±3 degrees of its centered position; and the magnitude of the steerable wheel error may fall within a range less than or slightly greater than a range of between 0 and 3 degrees. If the truck 10 is being steered beyond the control handle and steerable wheel position ranges, it is preferred for the truck 10 to come to a complete stop in response to the speed selection switch 98 being toggled during truck movement. Since the steerable-wheel-to-control-handle-position ratio changes in a stepped fashion in the illustrated embodiment, this will prevent rapid changes in the steerable wheel position if the truck 10 is being operated through a turn while moving and the switch 98 is toggled.


In a still further embodiment of the present invention, the display module 230 determines the steerable-wheel-to-control-handle-position ratio based on a position of a maneuverability switch (not shown) instead of the position of the speed selection switch 98.


When the maneuverability switch is located in a “low resolution” position, the display module 230 multiplies the current control handle position by a ratio equal to 90/60 or 1.5/1.0 in the illustrated embodiment to determine the desired angular position of the steerable wheel 74. When in the low resolution mode and the vehicle is operating at a low speed, steering is believed to be enhanced because the truck is more maneuverable. When the maneuverability switch is located in the “high resolution” position, the display module 230 multiplies the current control handle position by a ratio equal to 60/60 or 1.0/1.0 in the illustrated embodiment to determine the desired angular position of the steerable wheel 74. When in the high resolution mode and the vehicle is operating at a high speed, the control handle 90 always points in the same direction as the desired steered wheel position and the operator is provided with more steering resolution.


While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims
  • 1. A materials handling vehicle comprising: a frame comprising an operator's compartment;
  • 2. A materials handling vehicle as set out in claim 1, wherein said control apparatus selects said first ratio when said one select signal is equal to said low speed select signal and said control apparatus selects said second ratio when said one select signal is equal to said high speed select signal, said first ratio being greater than said second ratio.
  • 3. A materials handling vehicle as set out in claim 1, wherein said control apparatus changes said one steerable wheel-to-control handle-position ratio in response to said selection switch changing said one select signal and when said vehicle is stopped.
  • 4. A materials handling vehicle as set out in claim 1, wherein said control apparatus changes said one steerable wheel-to-control handle-position ratio in response to said selection switch changing said one select signal, said control handle being located in a position within a first predefined range, said steerable wheel being located in a position within a second predefined range and an error between a desired angular position of said steerable wheel and a determined actual position of said steerable wheel is equal to or less than a predefined value.
  • 5. The materials handling vehicle as set out in claim 4, wherein said first and second predefined ranges are equal to ±3 degrees of a centered position and said predefined value is equal to 3.
Parent Case Info

This application claims the benefit of: U.S. Provisional Application No. 61/026,151, filed Feb. 5, 2008 and entitled “A MATERIALS HANDLING VEHICLE HAVING A STEER SYSTEM INCLUDING A TACTILE FEEDBACK DEVICE”; U.S. Provisional Application No. 61/026,153, filed Feb. 5, 2008 and entitled “A MATERIALS HANDLING VEHICLE HAVING A CONTROL APPARATUS FOR DETERMINING AN ACCELERATION VALUE”; U.S. Provisional Application No. 61/049,158, filed Apr. 30, 2008 and entitled “A MATERIALS HANDLING VEHICLE HAVING A STEER SYSTEM INCLUDING A TACTILE FEEDBACK DEVICE”; U.S. Provisional Application No. 61/055,667, filed May 23, 2008 and entitled “A MATERIALS HANDLING VEHICLE WITH A MODULE CAPABLE OF CHANGING A STEERABLE WHEEL TO CONTROL HANDLE POSITION RATIO,” the disclosures of which are incorporated herein by reference.

US Referenced Citations (217)
Number Name Date Kind
2417850 Winslow Mar 1947 A
2575360 Rabinow Nov 1951 A
2645297 Wennberg et al. Jul 1953 A
2886151 Winslow May 1959 A
3332507 Bush Jul 1967 A
3720281 Frownfelter Mar 1973 A
3791474 Stammen et al. Feb 1974 A
3946825 Gail Mar 1976 A
4028597 Delaney et al. Jun 1977 A
4223901 Klemick Sep 1980 A
4287966 Frees Sep 1981 A
4336860 Noller et al. Jun 1982 A
4354568 Griesenbrock Oct 1982 A
4386674 Sugata Jun 1983 A
4392670 Schultz Jul 1983 A
4500818 Konrad et al. Feb 1985 A
4520299 Konrad May 1985 A
4588198 Kanazawa et al. May 1986 A
4716980 Butler Jan 1988 A
4771846 Venable et al. Sep 1988 A
4834203 Takahashi May 1989 A
4860844 O'Neil Aug 1989 A
4871040 Zuraski et al. Oct 1989 A
4936425 Boone et al. Jun 1990 A
4942529 Avitan et al. Jul 1990 A
4950126 Fabiano et al. Aug 1990 A
4992190 Shtarkman Feb 1991 A
5029823 Hodgson et al. Jul 1991 A
5032994 Wellman Jul 1991 A
5067576 Bober Nov 1991 A
5097917 Serizawa et al. Mar 1992 A
5151860 Taniguchi et al. Sep 1992 A
5167850 Shtarkman Dec 1992 A
5181173 Avitan Jan 1993 A
5194851 Kraning et al. Mar 1993 A
5247441 Serizawa et al. Sep 1993 A
5251135 Serizawa et al. Oct 1993 A
5277281 Carlson et al. Jan 1994 A
5284330 Carlson et al. Feb 1994 A
5293952 Ledamoisel et al. Mar 1994 A
5299648 Watanabe et al. Apr 1994 A
5315295 Fujii May 1994 A
5325935 Hirooka et al. Jul 1994 A
5347458 Serizawa et al. Sep 1994 A
5354488 Shtarkman et al. Oct 1994 A
5390756 Yokoyama Feb 1995 A
5428537 Kamono et al. Jun 1995 A
5457632 Tagawa et al. Oct 1995 A
5469947 Anzai et al. Nov 1995 A
5492312 Carlson Feb 1996 A
5517096 Shtarkman et al. May 1996 A
5539397 Asanuma et al. Jul 1996 A
5549837 Ginder et al. Aug 1996 A
5573088 Daniels Nov 1996 A
5576956 Ashizawa et al. Nov 1996 A
5579228 Kimbrough et al. Nov 1996 A
5579863 Nelson et al. Dec 1996 A
5598908 York et al. Feb 1997 A
5652704 Catanzarite Jul 1997 A
5657524 Kubala Aug 1997 A
5694313 Ooiwa Dec 1997 A
5721566 Rosenberg et al. Feb 1998 A
5732791 Pinkos et al. Mar 1998 A
5771989 Sangret Jun 1998 A
5779013 Bansbach Jul 1998 A
5835870 Kagawa Nov 1998 A
5842547 Carlson et al. Dec 1998 A
5845753 Bansbach Dec 1998 A
5908457 Higashira et al. Jun 1999 A
5947238 Jolly et al. Sep 1999 A
5948029 Straetker Sep 1999 A
5950518 Pfeifer Sep 1999 A
5964313 Guy Oct 1999 A
6000662 Todeschi et al. Dec 1999 A
6041882 Bohner et al. Mar 2000 A
6059068 Kato et al. May 2000 A
6070515 Urbach Jun 2000 A
6070681 Catanzarite et al. Jun 2000 A
6070691 Evans Jun 2000 A
6079513 Nishizaki et al. Jun 2000 A
6082482 Kato et al. Jul 2000 A
6089344 Baughn et al. Jul 2000 A
6091214 Yamawaki et al. Jul 2000 A
6097286 Discenzo Aug 2000 A
6112845 Oyama et al. Sep 2000 A
6112846 Mukai et al. Sep 2000 A
6116372 Mukai et al. Sep 2000 A
6138788 Bohner et al. Oct 2000 A
6202806 Sandrin et al. Mar 2001 B1
6219604 Dilger et al. Apr 2001 B1
6227320 Eggert et al. May 2001 B1
6234060 Jolly May 2001 B1
6256566 Kamiya et al. Jul 2001 B1
6262712 Osborne et al. Jul 2001 B1
6271828 Rosenberg et al. Aug 2001 B1
6279952 Van Wynsberghe et al. Aug 2001 B1
6283859 Carlson et al. Sep 2001 B1
6290010 Roudet et al. Sep 2001 B1
6300936 Braun et al. Oct 2001 B1
6302249 Jolly et al. Oct 2001 B1
6310604 Furusho et al. Oct 2001 B1
6339419 Jolly et al. Jan 2002 B1
6370459 Phillips Apr 2002 B1
6370460 Kaufmann et al. Apr 2002 B1
6373465 Jolly et al. Apr 2002 B2
6378671 Carlson Apr 2002 B1
6382604 St. Clair May 2002 B2
6389343 Hefner et al. May 2002 B1
6448728 Noro et al. Sep 2002 B2
6464025 Koeper et al. Oct 2002 B1
6475404 Carlson Nov 2002 B1
6484838 Borsting et al. Nov 2002 B1
6486872 Rosenberg et al. Nov 2002 B2
6491122 Leitner et al. Dec 2002 B2
6505703 Stout et al. Jan 2003 B2
6507164 Healey et al. Jan 2003 B1
6535806 Millsap et al. Mar 2003 B2
6547043 Card Apr 2003 B2
6550565 Thomas et al. Apr 2003 B2
6557662 Andonian et al. May 2003 B1
6564897 Dammeyer May 2003 B2
6595306 Trego et al. Jul 2003 B2
6609052 Radamis et al. Aug 2003 B2
6612392 Park et al. Sep 2003 B2
6612929 Fujimoto et al. Sep 2003 B2
6619444 Menjak et al. Sep 2003 B2
6625530 Bolourchi Sep 2003 B1
6636197 Goldenberg et al. Oct 2003 B1
6637558 Oliver et al. Oct 2003 B2
6640940 Carlson Nov 2003 B2
6655490 Andonian et al. Dec 2003 B2
6655494 Menjak et al. Dec 2003 B2
6659218 Thomas et al. Dec 2003 B2
6678595 Zheng et al. Jan 2004 B2
6681881 Andonian et al. Jan 2004 B2
6681882 Zheng et al. Jan 2004 B2
6688420 Zheng et al. Feb 2004 B2
6705424 Ogawa et al. Mar 2004 B2
6736234 Zheng et al. May 2004 B2
6752039 Kreuzer et al. Jun 2004 B2
6752425 Loh et al. Jun 2004 B2
6757601 Yao et al. Jun 2004 B1
6761243 Stout et al. Jul 2004 B2
6776249 Fortin Aug 2004 B2
6799654 Menjak et al. Oct 2004 B2
6817437 Magnus et al. Nov 2004 B2
6854573 Jolly et al. Feb 2005 B2
6883625 Trego et al. Apr 2005 B2
6899196 Husain et al. May 2005 B2
6910699 Cherney Jun 2005 B2
6912831 Velke et al. Jul 2005 B2
6920753 Namuduri Jul 2005 B2
6957873 Wanke et al. Oct 2005 B2
6962231 Carlsson et al. Nov 2005 B2
6968262 Higashi et al. Nov 2005 B2
6997763 Kaji Feb 2006 B2
6999862 Tamaizumi et al. Feb 2006 B2
7017689 Gilliland et al. Mar 2006 B2
7025157 Lindsay et al. Apr 2006 B2
7040427 Toomey May 2006 B2
7113166 Rosenberg et al. Sep 2006 B1
7165643 Bozem et al. Jan 2007 B2
7178613 Yanaka et al. Feb 2007 B2
7207411 Duits et al. Apr 2007 B2
7213678 Park May 2007 B2
7226069 Ueda et al. Jun 2007 B2
7234563 Ogawa et al. Jun 2007 B2
7240485 Namuduri et al. Jul 2007 B2
7257947 Namuduri Aug 2007 B2
7302329 McDonald et al. Nov 2007 B2
7353099 Lindsay et al. Apr 2008 B2
7720584 Ogawa et al. May 2010 B2
7831355 Nishiyama Nov 2010 B2
20010042655 Dammeyer Nov 2001 A1
20010052756 Noro et al. Dec 2001 A1
20020079157 Song Jun 2002 A1
20020087242 Kawashima Jul 2002 A1
20020095224 Braun et al. Jul 2002 A1
20030028306 Fujimori Feb 2003 A1
20030029648 Trego et al. Feb 2003 A1
20030079923 Johnson May 2003 A1
20030114270 Wuertz et al. Jun 2003 A1
20030168275 Sakugawa Sep 2003 A1
20040046346 Eki et al. Mar 2004 A1
20040099453 Guy May 2004 A1
20040104066 Sakai Jun 2004 A1
20040231902 Carlson et al. Nov 2004 A1
20050016779 Lindsay et al. Jan 2005 A1
20050023066 McGoldrick Feb 2005 A1
20050055149 Kato et al. Mar 2005 A1
20050087384 Magnus et al. Apr 2005 A1
20050199436 Schroder et al. Sep 2005 A1
20050247508 Gilliland et al. Nov 2005 A1
20050281656 Bozem et al. Dec 2005 A1
20060006027 Carlson et al. Jan 2006 A1
20060089778 Lindsay et al. Apr 2006 A1
20060090967 Bernd et al. May 2006 A1
20060169499 Gotz Aug 2006 A1
20060178799 Hoying et al. Aug 2006 A1
20060197741 Biggadike Sep 2006 A1
20060200291 Wroblewski Sep 2006 A1
20060225947 Nyberg Oct 2006 A1
20060231301 Rose et al. Oct 2006 A1
20060231302 Rose Oct 2006 A1
20060245866 Rose et al. Nov 2006 A1
20060259221 Murty et al. Nov 2006 A1
20070013655 Rosenberg et al. Jan 2007 A1
20070080037 Larry et al. Apr 2007 A1
20070095040 Berkeley May 2007 A1
20070137904 Rose et al. Jun 2007 A1
20070257552 Hehl Nov 2007 A1
20070278032 Sakaguchi et al. Dec 2007 A1
20090194357 Wetterer et al. Aug 2009 A1
20090194363 Crabill et al. Aug 2009 A1
20090198416 Wetterer et al. Aug 2009 A1
20090222168 Egenfeldt Sep 2009 A1
20100063682 Akaki Mar 2010 A1
Foreign Referenced Citations (86)
Number Date Country
2346604 Aug 2001 CA
3830836 Mar 1990 DE
19901451 Jul 2000 DE
10033107 Jan 2001 DE
102005011998 Oct 2005 DE
102005012004 Oct 2005 DE
602004009363 Mar 2008 DE
0442570 Aug 1991 EP
0726193 Aug 1996 EP
0872405 Oct 1998 EP
1013537 Jun 2000 EP
1125825 Apr 2002 EP
1533211 Oct 2004 EP
1481944 Dec 2004 EP
1505034 Feb 2005 EP
1655211 May 2006 EP
1475297 Dec 2007 EP
649553 Jan 1951 GB
2087513 May 1982 GB
2263179 Jul 1993 GB
2310413 Aug 1997 GB
2351953 Jan 2001 GB
2378165 Feb 2003 GB
2404179 Jan 2006 GB
39759 Jan 1939 JP
57120730 Jul 1982 JP
60080969 May 1985 JP
61070617 Apr 1986 JP
61196863 Sep 1986 JP
61275059 Dec 1986 JP
62198564 Sep 1987 JP
63082873 Apr 1988 JP
1131348 May 1989 JP
2120527 May 1990 JP
02212272 Aug 1990 JP
04108071 Apr 1992 JP
4108071 Apr 1992 JP
04133860 May 1992 JP
4357312 Dec 1992 JP
4358967 Dec 1992 JP
4372471 Dec 1992 JP
06087453 Mar 1994 JP
06092246 Apr 1994 JP
6107026 Apr 1994 JP
06255522 Sep 1994 JP
07165091 Jun 1995 JP
07269604 Oct 1995 JP
8117588 May 1996 JP
8127790 May 1996 JP
08253159 Oct 1996 JP
08277853 Oct 1996 JP
08292712 Nov 1996 JP
08337171 Dec 1996 JP
09142330 Jun 1997 JP
09226607 Sep 1997 JP
10171542 Jun 1998 JP
10177378 Jun 1998 JP
10184758 Jul 1998 JP
10217998 Aug 1998 JP
10226346 Aug 1998 JP
10250617 Sep 1998 JP
10297519 Nov 1998 JP
10307661 Nov 1998 JP
11132259 May 1999 JP
2914165 Jun 1999 JP
11255134 Sep 1999 JP
11513192 Nov 1999 JP
2000072399 Mar 2000 JP
2000181618 Jun 2000 JP
2001352612 Dec 2001 JP
2003306160 Oct 2003 JP
2004090758 Mar 2004 JP
2004140908 May 2004 JP
2005096894 Apr 2005 JP
2005170136 Jun 2005 JP
2007130309 May 2007 JP
2007168617 Jul 2007 JP
20020044975 Jun 2002 KR
20040096679 Nov 2004 KR
9642078 Dec 1996 WO
9715058 Apr 1997 WO
9926230 May 1999 WO
03010040 Feb 2003 WO
2006113510 Oct 2006 WO
2006113510 Oct 2006 WO
2007106714 Sep 2007 WO
Related Publications (1)
Number Date Country
20090194358 A1 Aug 2009 US
Provisional Applications (4)
Number Date Country
61026151 Feb 2008 US
61026153 Feb 2008 US
61049158 Apr 2008 US
61055667 May 2008 US