INVENTOR: Ash M. Genaidy

TITLE OF THE INVENTION: Rotating Forklift Cab With Digital Operating

Controls

ATTORNEY DOCKET NO: PCT-081906-G

Related Application

The present international patent application is related to U.S. Provisional Application for Patent No. 60/709,309 filed August 19, 2005, entitled identically with the present application, and incorporated herein by reference in its entirety.

Technical Field

This invention relates to a self-contained rotating cab for a forklift truck encompassing digital operating controls. More particularly, the invention relates to a cab ■ design that allows the operator to operate the forklift normally during forward movement, but allows the entire cab to rotate 180 degrees when the operator wants to operate the cab in the reverse direction. The cab design requires incorporation of digital operating controls, including forward/reverse, steering , speed, braking, and forklift controls that operate properly regardless of the position of the cab or the direction of vehicle movement.

Background Art

Forklifts are widely used in manufacturing, service, and warehousing enterprises, with an estimated 1.2 million workers operating as many as 800,000 forklifts in the U.S. alone (Swartz, 1998). A number of occupational hazards associated with operation of

forklifts have been identified. Fatalities and traumatic injuries associated with forklift operations are well documented (Collins et al., 1999a, 1999b, 1999c; NIOSH, 2001; Miller, 1988; Stout- Wiegland, 1988; Swartz, 1998). It is estimated that, each year in the US, nearly 100 workers are killed and another 20,000 are seriously injured in forklift- related incidents, involving crashes and overturns, with overturns being the leading cause of forklift fatalities and representing 25% of all forklift-related deaths (NIOSH, 2001). In a case-control study by Collins et al. (1999a), the possible risk factors associated with collision injuries include internal environment characteristics (Obstruction, volume of pedestrian traffic, presence of stop signs, aisle widths) as well as vehicle characteristics (vehicle loaded). In another study by Collins et al. (1999b), the five most frequent characteristics of fatal forklift incidents include pedestrian struck by, overturns, crushed by forklift, worker fell from forklift, and forklift fell on worker. hi addition to the increased risk of fatalities and traumatic injuries, however, forklift operators may also be at a significantly increased risk of musculoskeletal disorders (MSDs) (e.g., Bovenzi et al., 2002). The potential risk factors that may lead to musculoskeletal disorders among forklift operators, include: 1) static sedentary position while driving (hands and feet steady on handles and pedals); 2) repeated exposure to short and long-term awkward trunk postures (trunk twisting and bending), especially during reverse operation; 3) repeated exposure to short and long-term awkward neck postures during reverse operation; and, 4) exposure to whole-body vibration while driving (National Safety Council, 1982; Brendstrup and Biering-Sorensen, 1987). Currently, US statistics on the prevalence of musculoskeletal disorders among forklift operators are not readily available.

Recently, a systematic review and a critical appraisal of the epidemiological studies relating forklift operation to MSDs were conducted. The systematic review of these studies consisted of: 1) describing the evidence in terms of exposure, outcome, study design, study population, and main results; and 2) deriving a meta-risk estimate from the reviewed studies. Seven epidemiological studies were identified that examined the relationship between forklift operation and development of MSDs. In general, these observational studies reported significant associations between forklift operation as an occupation and musculoskeletal disorders. A meta-odds ratio was calculated to determine if forklift operators are at increased risk of having lower back pain as compared to those who do not operate forklifts. The author found that the meta-odds ratio for forklift operators having lower back pain compared to a non-exposed control group was 2.125 and was significant at the 5% level. In light of this, it is likely that forklift operators are at increased risk of having lower back pain compared to workers who do not operate forklifts. None of the studies examined the association between driving a forklift and neck pain. It is likely, however, that forklift operators may also be at increased risk of neck problems due to extreme neck rotation during forklift operation.

No studies were found that had documented the magnitude of twisting the neck and trunk during reverse operation of the forklift vehicle. In addition to the risk of MSDs associated with reverse operation of a forklift, the field of vision is extremely restricted which may result in increased risk of collisions with other objects and people.

Summary of the Invention

A rotating forklift cab according to the present invention basically comprises: (1) a support base capable of at least 180 degree rotation; (2) a seat mounted on the support base for the vehicle operator; (3) digital speed, forward/reverse, steering, braking and lift controls mounted on the support base; (4) a CPU connected to the foregoing controls; (5) a plurality of sensors connected to the CPU; and (6) digital speed, forward/reverse, steering, braking and lift actuating components connected to the CPU.

Objects of the Invention

One object of the invention is to eliminate the need for extreme trunk and neck twisting by the operator during forklift operation in the reverse direction.

Another object of the invention is to reduce the risk of collision during forklift operation by increasing the field of vision of the operator during reverse movement.

Yet another object of the invention is to provide digital operating controls that will allow accurate control of the vehicle regardless of the cab orientation or the direction of movement of the vehicle.

These and other objectives are carried out by rotating forklift cab with digital operating controls having a fixed base capable of 360 degree rotation and mounted seat and operating controls linked by digital controllers to the actuator mechanism.

Brief description of the drawings:

Figure 1 is a diagram of input devices, CPU, and digital controllers for a forklift according to the present invention;

Figure 2 is a conceptual image of the present invention with the cab facing in a forward direction;

Figure 3 is a conceptual image of the present invention with the cab facing in a reverse direction;

Figure 4 is a diagram of a forward/reverse control components for the present invention;

Figure 5 is a diagram of steering components for the present invention;

Figure 6 is a diagram of braking components for the present invention;

Figure 7 is a diagram of speed control components for the present invention; and

Figure 8 is a diagram of cargo lifting/lowering components for the present invention. Detailed Description of the Invention

As illustrated in FIGS. 1-3, the rotating cab with digital operating controls consists of five operator input devices that are connected to a central processing unit (CPU) 10. The five input devices provide information from the operator to the CPU about the desired functions of the forklift. The five input devices include the following:

1. Steering input (steering wheel with digital sensor) 12;

2. Speed input (foot pedal with digital sensor) 14;

3. Brake input (foot pedal with digital sensor) 16;

4. Forward/Reverse input (hand lever with digital sensor) 18;

5. Lifting/Lowering input (hand lever with digital sensor) 20

The five input devices are mounted on a rotating cab base 22. Depending upon the desired direction of travel, the operator changes the position of the forward/reverse lever

18, which automatically rotates the cab to either a forward or backward position relative to the frame 24 of the forklift. A digital position sensor 26 detects whether the cab is facing forward or backward and sends a signal to the CPU 10 about the desired direction of movement.

As illustrated in FIGS. 4-8, the CPU 10 processes the sensor data from the input devices 12-20 from the operator and sends the proper signals to five movement controllers/motors 28-36 to properly turn the wheels 38 the correct direction, set the gear box 40 for the desired direction of travel, control the speed of the drive motor 42, control the braking mechanism 44, and control the lift mechanism 46, as requested by the operator through the input devices. The CPU will use the input from the cab rotation sensor and the input devices to control the movement and function of the forklift. Forward/Reverse:

A rotation sensor 26 (FIG. 1) measures the rotation position of the cab. If operating in the forward mode (FIG. 2), the cab will be in its default position facing forward, if operating in the reverse mode (FIG. 3), the cab will rotate 180 degrees to face the backward direction. The forward/reverse lever 18 (FIGS. 2 and 3) sends a signal to the CPU 10, which sets the appropriate direction codes for output to the forward/reverse controller 28 that controls the gear box 40 and the cab rotator 42.

Steering:

The steering input will be a steering wheel 12 (FIGS. 2, 3) that outputs digital signals and sends them to the CPU 10. The CPU then sends the signals to a

steering controller 30 (FIGS. 1, 5) that controls the steering motor 48 to turn the wheels 38.

Speed:

The speed input will be a foot pedal 14 (FIGS. 2, 3) that outputs digital signals and sends them to the CPU 10. The CPU then sends the signals to a speed controller 32 (FIGS. 1, 7) that controls the drive motor 42 to increase or decrease the speed of the forklift.

Braking:

The braking input will be a foot pedal 16 (FIGS. 2, 3) that outputs digital signals and sends them to the CPU 10. The CPU then sends the signals to a brake controller 34 (FIGS. 1, 6) that controls the brake actuator 44 to decelerate or stop the forklift.

Lifting/Lowering:

The lifting/lowering input device will be a lever or stick 20 (FIGS. 2, 3) mounted on the cab base 22 that outputs digital signals and sends them to the CPU 10. The CPU will then send signals to the lifting controller 36 (FIGS. 1, 8) that controls the lifting motor to initiate the function requested by the operator.

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