EP3228582B1 - Opto-electric system of enhanced operator control station protection - Google Patents
Opto-electric system of enhanced operator control station protection Download PDFInfo
- Publication number
- EP3228582B1 EP3228582B1 EP17163943.8A EP17163943A EP3228582B1 EP 3228582 B1 EP3228582 B1 EP 3228582B1 EP 17163943 A EP17163943 A EP 17163943A EP 3228582 B1 EP3228582 B1 EP 3228582B1
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- European Patent Office
- Prior art keywords
- sensor
- platform
- control panel
- switch
- panel area
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66F—HOISTING, LIFTING, HAULING OR PUSHING, NOT OTHERWISE PROVIDED FOR, e.g. DEVICES WHICH APPLY A LIFTING OR PUSHING FORCE DIRECTLY TO THE SURFACE OF A LOAD
- B66F9/00—Devices for lifting or lowering bulky or heavy goods for loading or unloading purposes
- B66F9/06—Devices for lifting or lowering bulky or heavy goods for loading or unloading purposes movable, with their loads, on wheels or the like, e.g. fork-lift trucks
- B66F9/075—Constructional features or details
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66F—HOISTING, LIFTING, HAULING OR PUSHING, NOT OTHERWISE PROVIDED FOR, e.g. DEVICES WHICH APPLY A LIFTING OR PUSHING FORCE DIRECTLY TO THE SURFACE OF A LOAD
- B66F11/00—Lifting devices specially adapted for particular uses not otherwise provided for
- B66F11/04—Lifting devices specially adapted for particular uses not otherwise provided for for movable platforms or cabins, e.g. on vehicles, permitting workmen to place themselves in any desired position for carrying out required operations
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66F—HOISTING, LIFTING, HAULING OR PUSHING, NOT OTHERWISE PROVIDED FOR, e.g. DEVICES WHICH APPLY A LIFTING OR PUSHING FORCE DIRECTLY TO THE SURFACE OF A LOAD
- B66F17/00—Safety devices, e.g. for limiting or indicating lifting force
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66F—HOISTING, LIFTING, HAULING OR PUSHING, NOT OTHERWISE PROVIDED FOR, e.g. DEVICES WHICH APPLY A LIFTING OR PUSHING FORCE DIRECTLY TO THE SURFACE OF A LOAD
- B66F17/00—Safety devices, e.g. for limiting or indicating lifting force
- B66F17/006—Safety devices, e.g. for limiting or indicating lifting force for working platforms
Definitions
- the invention relates to work platforms and, more particularly, to a work platform including provisions to enhance protection for an operator from sustained involuntary operation resulting in an impact with an obstruction or structure.
- Lift vehicles including aerial work platforms, telehandlers such as rough terrain fork trucks with work platform attachments, and truck mounted aerial lifts are known and typically include an extendible boom, which may be positioned at different angles relative to the ground, and a work platform at an end of the extendible boom.
- a control console including various control elements that may be manipulated by the operator to control such functions as boom angle, boom extension, rotation of the boom and/or platform on a vertical axis, and where the lift vehicle is of the self-propelled type, there are also provided engine, steering and braking controls.
- a safety hazard can occur in a lift vehicle including a work platform when an operator is positioned between the platform and a structure that may be located overhead or behind the operator, among other places.
- the platform may be maneuvered into a position where the operator is crushed between that structure and the platform, resulting in serious injury or death.
- Document JP H05 124800 A discloses a system for protecting an operator on an aerial work platform from a crushing hazard, the aerial work platform including a floor structure, a safety rail coupled with the floor structure and defining a personnel work area, and a control panel area, the system comprising a sensor positionable adjacent the control panel area, the sensor including a first transmitter unit positioned on one side of the control panel and a first receiver unit positioned on an opposite side of the control panel area, the first transmitter unit emitting a light beam across the control panel area to the first receiver unit, the system further comprising a control system communicating with the sensor and cooperable with driving components of the aerial work platform, the control system being programmed to control operation of the driving components based on signals from the sensor, and wherein the sensor comprises a housing for each of the first transmitter unit and the first receiver unit, the housings being attachable to the safety rail.
- JP H05 124800 A also discloses another sensor including a second transmitter unit; a second receiver unit, wherein the second transmitter unit and the second receiver unit are positioned on an operator side of the first transmitter unit and the first receiver unit, respectively; and wherein the second transmitter unit emits a second light beam across the control panel area to the second receiver unit.
- a platform it would be desirable for a platform to incorporate protective structure to enhance protection of the operator from continued involuntary operation of the machine upon impacting an obstruction or structure.
- the protecting structure can also serve as a physical barrier to enhance protection for the operator and/or cooperate with the drive/boom functions control system to cease or reverse movement of the platform. If cooperable with the operating components of the machine, it is also desirable to prevent inadvertent tripping of the protective structure.
- an opto-electric sensor based system provides enhanced protection against sustained operation for aerial work platforms.
- the sensor is designed to be clamped to the safety rail of the platform.
- the system incorporating an opto-electric sensor is an improvement over existing systems that utilize physical contact with a switch or the like for activation. In the previous systems, the operator must make physical contact with a switch in order to activate an enhanced operator protection system.
- the system according to the described embodiments resolves drawbacks of the existing system with respect to obstruction of visibility and sensitivity of the shear blocks to accidental shear that result in a service call.
- a personnel lift includes a vehicle chassis, a lifting assembly secured to the vehicle chassis, and a work platform attached to the lifting assembly.
- the work platform includes a floor structure, a safety rail coupled with the floor structure and defining a personnel work area, and a control panel area.
- a control box is disposed in the control panel area and includes an operator input implement.
- Driving components cooperable with the lifting assembly provide for lifting and lowering the work platform.
- a sensor is positioned adjacent the control panel area and includes a transmitter unit mounted to the safety rail on one side of the control box and a receiver unit mounted to the safety rail on an opposite side of the control box. The transmitter unit emits a light beam across the control panel area to the receiver unit.
- a control system communicating with the driving components, the control box, and the sensor controls operation of the driving components based on signals from the operator input implement and the sensor.
- the senor may be positioned above and in front of the control panel area.
- the control system may be programmed to shut down the driving components when the light beam from the transmitter unit may be not received by the receiver unit.
- the control system may be programmed to modify operating parameters of the driving components when the light beam from the transmitter unit is not received by the receiver unit.
- the sensor may include two receiver units that are positioned to receive the light beam from the transmitter unit.
- the control system may be programmed to prevent operation of the driving components when one or both of the receiver units do not detect the light beam. Additionally, the control system may be programmed to reverse a last operation by the driving components when one or both of the receiver units do not detect the light beam for a predetermined period of time, which may be at most one second.
- the lift may include an override switch communicating with the control system to permit operation of the driving components at creep speed despite that the receiver unit does not detect the light beam.
- the sensor may include a first housing in which the transmitter unit is disposed and a second housing in which the receiver unit is disposed, where the first and second housings include respective clamps for attaching the housings to the safety rail.
- a window opening may be provided in each of the first and second housings and a window may be disposed in each of the window openings, where the windows are positioned adjacent the transmitter unit and the receiver unit, respectively. The windows may protrude from a surface of the housings.
- the lift may additionally include a warning system positioned adjacent the control panel area on an operator side of the sensor.
- the warning system may include a warning transmitter unit mounted on the one side of the control box, a warning receiver unit mounted on the opposite side of the control box, and an indicator lamp.
- the warning transmitter unit emits a second light beam across the control panel area to the warning receiver unit.
- the control system may be programmed to change the indicator lamp when the second light beam from the warning transmitter unit is not received by the warning receiver unit.
- a system for protecting an operator on an aerial work platform from a crushing hazard including a floor structure, a safety rail coupled with the floor structure and defining a personnel work area, and a control panel area
- the system comprising a sensor positionable adjacent the control panel area, the sensor including a first transmitter unit positioned on one side of the control panel area and a first receiver unit positioned on an opposite side of the control panel area, the first transmitter unit emitting a light beam across the control panel area to the first receiver unit
- the system further comprising a control system communicating with the sensor and cooperable with driving components of the aerial work platform, the control system being programmed to control operation of the driving components based on signals from the sensor
- the sensor comprising a housing for each of the first transmitter unit and the first receiver unit, the housings being attachable to the safety rail
- the sensor further comprises a warning system including: a second transmitter unit disposed in one of the housings; a second receiver unit disposed in the other of
- a personnel lift including a vehicle chassis, a lifting assembly secured to the vehicle chassis, and a work platform attached to the lifting assembly.
- a control box is disposed in the control panel area and includes an operator input implement. Driving components cooperable with the lifting assembly lift and lower the work platform.
- An opto-electric sensor positioned adjacent the control panel area is configured to detect an object entering the control panel area.
- a control system communicating with the driving components, the control box, and the sensor controls operation of the driving components based on signals from the operator input implement and the sensor.
- FIG. 1 illustrates an exemplary typical aerial lift vehicle including a vehicle chassis 2 supported on vehicle wheels 4.
- a turntable and counterweight 6 are secured for rotation on the chassis 2, and an extendible boom assembly is pivotably attached at one end to the turntable 6.
- An aerial work platform 10 is attached at an opposite end of the extendible boom 8.
- the illustrated lift vehicle is of the self-propelled type and thus also includes a driving/control system (illustrated schematically in FIG. 1 at 12 ) and a control console 14 on the platform 10 with various control elements that may be manipulated by the operator to control such functions as boom angle, boom extension, rotation of the boom and/or platform on a vertical axis, and engine, steering and braking controls, etc.
- FIGS. 2 and 3 show an exemplary work platform 10 including a protection envelope according to a first embodiment of the invention.
- the platform 10 includes a floor structure 20, a safety rail 22 coupled with the floor structure 20 and defining a personnel work area, and a control panel area 24 in which the control panel 14 is mounted.
- the protection envelope surrounds the control panel area 24 and serves to enhance protection for the operator from an obstruction or structure that may constitute a crushing hazard.
- the protection envelope may include protection bars 26 on either side of the control panel area 24 extending above the safety rail 22.
- the safety rail 22 includes side sections (the longer sections in Figs. 2 and 3 ) and end sections (the shorter sections in Figs. 2 and 3 ).
- the control panel area 24 may be positioned within one of the side sections.
- the protection bars 26 are disposed intermediately within the one of the side sections adjacent the control panel area 24.
- the protection bars 26 may be disposed in alignment with the end sections of the safety rail 22 (as shown in dashed line in FIG. 3 ).
- the protection bars 26 extend above the safety rail 22 by an amount sufficient to accommodate an anteroposterior diameter of an adult human (i.e., a distance between a person's front and back). In this manner, if an obstacle is encountered that could result in crushing the operator between the structure and the control panel 14, the operator will be protected from injury by the protection bars 26 with sufficient space between the control panel 14 and a top of the protection bars 26 to accommodate the operator's torso.
- FIG. 3 shows the user in a "safe" position where an encountered structure is prevented from crushing the operator by the protection bars 26.
- the protection envelope includes a switch bar 28 secured in the control panel area 24.
- a platform switch 30 is attached to the switch bar 28 and includes sensors for detecting the application of a force, such as by an operator being pressed into the platform switch by an obstruction or structure.
- the platform switch 30 is configured to trip upon an application of a predetermined force.
- the force causing the platform switch 30 to be tripped may be applied to the platform switch 30 itself or to the switch bar 28 or to both. It has been discovered that inadvertent tripping can be avoided if the predetermined force is about 40-50 lbs over a 6" sensor (i.e., about 6.5-8.5 lbs/in).
- the switch bar 28 and the platform switch 30 are positioned between the personnel work area and the safety rail 22. Relative to the floor structure, the switch bar 28 and the platform switch 30 are positioned above and in front of the control panel area 24. Based on an ergonomic study, it was discovered that the switch bar 28 and platform switch 30 should be positioned about 50" above the platform floor.
- the switch 30 includes a switch housing 32 with internal ribs 34 connected between the switch housing and a pressure switch 36. Sensitivity can be adjusted by selecting a different rating pressure switch 36 and/or by adjusting the number, shape and stiffness of the ribs 34.
- the switch bar 28 and platform switch 30 also serve as a handle bar that an operator can grab in an emergency.
- FIGS. 6 and 7 An alternative platform switch assembly 301 is shown in Figs. 6 and 7 .
- the switch assembly 301 includes a platform switch 302 with injection molded end caps 303 and die cast mounting brackets 304.
- the platform switch 302 operates in a similar manner to the switch 30 shown in FIGS. 4 and 5 .
- An exemplary suitable switch for the platform switch is available from Tapeswitch Corporation of Farmingdale, NY.
- the platform switch 30, 302 and switch bar 28 may be secured to the control panel area 24 via a shear element 38.
- the shear element 38 includes a reduced diameter section as shown that is sized to fail upon an application of a predetermined force.
- the predetermined force at which the shear element 38 would fail is higher than the force required to trip the platform switch 30, 301.
- nylon may be used as the material for the shear element 38, since nylon has low relative elongation to plastic. Of course, other materials may be suitable.
- the driving components of the vehicle that are cooperable with the lifting assembly for lifting and lowering the work platform are controlled by an operator input implement on the control panel 14 and by the driving/control system 12 communicating with the driving components and the control panel 14.
- the control system 12 also receives a signal from the platform switch 30, 302 and controls operation of the driving components based on signals from the operator input implement and the platform switch 30, 302.
- the control system 12 is programmed to shut down driving components when the platform switch 30, 302 is tripped.
- the control system 12 may reverse the last operation when the platform switch 30, 302 is tripped.
- function cutout when the platform switch is tripped, the active function will be stopped immediately, and all non-active functions shall not be activated.
- a reversal function when the platform sensor is tripped during operation, the operation required RPM target is maintained, and the active function only when the trip occurred is reversed until the reversal function is stopped.
- a ground horn and a platform horn can be activated when the reversal function is active.
- engine RPM is set to low, and all functions are disabled until the functions are re-engaged with the foot switch and operator controls.
- the system may include a platform switch override button that is used to override the function cut out initiated by the platform switch.
- override button If the override button is pressed and held, it enables the hydraulic functions if the foot switch and controls are re-engaged sequentially. In this event, function speed is set in creep mode speed automatically.
- the controller is programmed to avoid the cut out feature being disabled before the platform switch is tripped regardless of whether the override button is pressed or released. This assures that the cut out feature will still be available if the override button is stuck or manipulated into an always-closed position.
- the reversal function is implemented for various operating parameters of the machine. For vehicle drive, if drive orientation shows that the boom is between the two rear wheels, reversal is allowed only when the drive backward is active and the platform switch is tripped. If a drive forward request is received when the platform switch is tripped, it is treated as a bump or obstacle in the road and will not trigger the reversal function. If the drive orientation shows that the boom is not in line with the rear wheels, then both drive forward and drive backward may trigger the reversal function. Additional operating parameters that are implemented with the reversal function include main lift, tower lift, main telescope (e.g., telescope out only), and swing.
- Reversal function terminates based on the platform switch signal, footswitch signal and time parameters that are set for different functions, respectively. If the platform switch changes from trip status to non-trip status before the maximum reversal time is elapsed, then the reversal function will be stopped; otherwise, the reversal function is active until the maximum reversal time is elapsed.
- ground control can be accessed from the ground via a switch.
- the platform switch In the ground control mode, if the platform switch is engaged, boom operation is allowed to operate in creep speed. If the platform switch changes status from engaged to disengaged, then operation is maintained in creep speed unless the ground enable and function control switch is re-engaged.
- FIGS. 9-11 show an alternative work platform 110 including a floor structure 120, a safety rail 122 coupled with the floor structure 120, and a control panel area 124 to which the control panel (not shown) is mounted.
- the switch bar 28 and platform switch 30 are secured in the control panel area 124.
- the control panel area 124 includes a sensor support bar 126 having a top crossbar 128 extending along a width dimension (W in FIG. 9 ) and sidebars 130 extending substantially perpendicularly from the top crossbar 128.
- the sidebars 130 define a width of the control panel area 124.
- the sensor support bar 126 is preferably bent from a single piece of material, although multiple pieces can be attached to one another in the arrangement shown.
- Each of the sidebars 130 may include an upper section extending from the top crossbar inward in a depth dimension (D in FIG. 9 ) to a bent section.
- a lower section preferably extends from the bent section outward in the depth dimension to the safety rail 122.
- the upper section of the sidebars 130 may be angled downwardly from the top crossbar 128 to the bent section.
- the lower section may extend at an angle from the bent section to the safety rail 122. As shown, the lower section may extend in a substantially straight line from the bent section to the safety rail.
- the safety rail 122 extends above the floor structure 120 to a rail height, where the lower sections of the sidebars 130 connect to the safety rail 122 at a position about halfway between the floor structure 120 and the rail height.
- the top crossbar 128 is preferably positioned above the rail height.
- the switch bar 28 and the platform switch 30 may be connected to the sensor support bar 126 at the bent sections of the sidebars 130 as shown.
- the platform switch is positioned inward in the depth dimension D of the floor structure such that an operator in the control panel area is closer to the platform switch 30 than to the safety rail 122.
- the switch bar and platform switch are under-mounted on the sensor support bar 126 relative to an operator standing on the floor structure 120. That is, as shown in FIGS. 10 and 11 , the switch bar 28 is preferably coupled to an outside surface of the sensor support bar 126 on an opposite side of the sensor support bar 126 relative to a position of an operator standing on the platform.
- the under-mounted configuration results in a simpler assembly (e.g., without brackets 304) and improved ergonomics.
- FIG. 11 is a close-up view of the switch bar 30 secured to the sensor support bar 126.
- a block 132 is fixed (e.g., by welding) to the sensor support bar 126
- a block holder 134 is fixed (e.g., by welding) to the block 132.
- the block holder 134 receives a shear block 136 of the switch bar 30 and is secured by a fastener 138 such as a bolt or the like.
- a similar bolt (not shown) secures the switch bar 30 to the shear block 136.
- FIGS. 12-14 show another alternative embodiment, which utilizes an opto-electric sensor for detecting an object such as an operator entering the control panel area 124.
- the personnel lift includes a vehicle chassis, a lifting assembly secured to the vehicle chassis, and a work platform attached to the lifting assembly.
- the work platform includes a floor structure, a safety rail 122 coupled with the floor structure and defining a personnel work area, and a control panel area. See, for example, FIGS. 1-3 and 9 .
- a control panel or control box 14 is disposed in the control panel area 124 and includes one or more operator input elements 125.
- driving components are cooperable with the lifting assembly for lifting and lowering the work platform.
- a sensor 402 is positioned adjacent the control panel area 124. Relative to the floor structure 20 (see FIGS. 2 , 3 and 9 ), the sensor 402 is positioned above and in front of the control panel area.
- the sensor 402 includes a transmitter unit 404 mounted to a side bar 130 of the safety rail 122 on one side of the control box 14 and a receiver unit 406 mounted to a side bar 130 of the safety rail 122 on an opposite side of the control box 14.
- the transmitter unit 404 emits a light beam across the control panel area 124 to the receiver unit 406.
- the control system 12 (shown schematically in FIG. 1 ) communicates with the driving components, the control box 14 and the sensor 402.
- the control system 12 controls operation of the driving components based on signals from the operator input element(s) 125 and the sensor 402.
- the receiver unit 406 is actually two receiver units that are both positioned to receive the light beam emitted from the transmitter unit 404 (see FIG. 14 ). In use, if the light beam from the transmitter unit 404 is detected by the receiver unit 406 (or both receiver units in the embodiment where two receiver units 406 are provided), the machine is allowed to operate normally. If the receiver unit 406 (or either or both receiver units 406 in the embodiment utilizing two receiver units) does not detect the transmitter beam (such as if the operator leans over the platform control box 14), the control system is programmed to stop machine functions, and further operation from the platform is prevented. Additionally, the control system may be programmed to reverse a last operation by the driving components when one or both of the receiver units 406 do not detect the light beam for a predetermined period of time, which at most may be one second or less.
- the system may include an override switch on the platform control box 14 to allow function use at reduced (creep) speed. Normal operation of the machine is prevented until the receiver unit 406 (or both receiver units 406) detect the transmitter beam.
- the senor 402 may include a housing 408 in which the transmitter unit 404 is disposed and a housing 410 in which the one or more receiver units 406 are disposed (see also FIG. 14 ).
- the housings include respective clamps 412 for securing the housings to the side bars 130 of the safety rail 122.
- the housings include a window opening 414 and a window 416 disposed in each of the window openings 414.
- the windows 416 are positioned adjacent the transmitter unit 404 and the receiver unit(s) 406, respectively.
- the windows 416 protrude outward of the housing surface to facilitate cleaning (e.g., scraping paint, removing dirt, concrete spray, etc.).
- FIG. 15 shows a modified sensor system incorporating an extra transmitter/receiver pair 418 as part of a warning or teaching system. That is, the extra transmitter/receiver pair 418 communicates the status of the system to the operator and teaches the operator of the location in which the sensor is active.
- the additional transmitter/receiver pair 418 is positioned adjacent the control panel area 124 on an operator side of the sensor 402.
- the transmitter/receiver pair 418 includes a warning transmitter unit mounted on one side of the control box 14, a warning receiver unit mounted on the opposite side of the control box 14, and an indicator lamp 420.
- the warning transmitter unit emits a second light beam across the control panel area 124 to the warning receiver unit, and the control system is programmed to change the indicator lamp 420 when the second light beam from the warning transmitter unit is not received by the warning receiver unit.
- the indicator lamp 420 (or set of lamps) is changed, either turned off or changed from one color to another such as green to red.
- the indicator light or lights provide the operator with information that the system is ready and functioning and help the operator to develop proper habits, e.g., teaching the operator to remain in the proper position relative to the control box to facilitate smooth and uninterrupted operation of the machine.
- the control system when power is applied to the machine control system, the control system may perform a diagnostic check of the receiver and transmitter system.
- the control system applies power in a predetermined orderly way to the receiver unit(s) and transmitter unit(s).
- the output values of the receiver units are evaluated by the control system for each powered state in order to detect faults with the components and/or wiring.
- the possible states are: R1 R2 T1 OFF OFF OFF OFF ON OFF ON ON ON OFF ON OFF ON OFF ON OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON
- the senor may be integrated with the platform control box 14 as shown in FIG. 16 .
- the sensor 4021 is positioned above and in front of the control panel area and is integrated with the control box 14.
- the sensor 4021 includes a transmitter unit 4041 on one side of the control box 14 and a receiver unit 4061 on an opposite side of the control box 14.
- the transmitter unit 4041 emits a light beam 4022 across the control panel area to the receiver unit 4061. The remaining operation is the same as that in the previously described embodiments.
- the sensors are preferably industrial photoelectric "light barrier” type sensors, where light and/or reference to a "light beam” is understood to cover a wide range of wavelengths - visible, infrared, laser, etc.
- the system may utilize receiver units with two complementary outputs. The complementary outputs are monitored in order to detect possible faults in components and wiring.
- the system may include a dedicated control module for operation and control of the transmitter, receiver and status lights (if any) including a machine platform control module interface.
- the dedicated control module may also perform diagnostics on the transmitter unit and the receiver unit(s).
- the sensor may include two discrete receiver units to provide redundancy.
- the sensor may include two discrete transmitter units and two discrete receiver units. Still further, the sensor may include a single transmitter unit and two discrete receiver units.
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- Civil Engineering (AREA)
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- Safety Devices In Control Systems (AREA)
Description
- The invention relates to work platforms and, more particularly, to a work platform including provisions to enhance protection for an operator from sustained involuntary operation resulting in an impact with an obstruction or structure.
- Lift vehicles including aerial work platforms, telehandlers such as rough terrain fork trucks with work platform attachments, and truck mounted aerial lifts are known and typically include an extendible boom, which may be positioned at different angles relative to the ground, and a work platform at an end of the extendible boom. On or adjacent the platform, there is typically provided a control console including various control elements that may be manipulated by the operator to control such functions as boom angle, boom extension, rotation of the boom and/or platform on a vertical axis, and where the lift vehicle is of the self-propelled type, there are also provided engine, steering and braking controls.
- A safety hazard can occur in a lift vehicle including a work platform when an operator is positioned between the platform and a structure that may be located overhead or behind the operator, among other places. The platform may be maneuvered into a position where the operator is crushed between that structure and the platform, resulting in serious injury or death.
- Document
JP H05 124800 A JP H05 124800 A - It would be desirable for a platform to incorporate protective structure to enhance protection of the operator from continued involuntary operation of the machine upon impacting an obstruction or structure. The protecting structure can also serve as a physical barrier to enhance protection for the operator and/or cooperate with the drive/boom functions control system to cease or reverse movement of the platform. If cooperable with the operating components of the machine, it is also desirable to prevent inadvertent tripping of the protective structure.
- In some embodiments, an opto-electric sensor based system provides enhanced protection against sustained operation for aerial work platforms. The sensor is designed to be clamped to the safety rail of the platform. The system incorporating an opto-electric sensor is an improvement over existing systems that utilize physical contact with a switch or the like for activation. In the previous systems, the operator must make physical contact with a switch in order to activate an enhanced operator protection system. The system according to the described embodiments resolves drawbacks of the existing system with respect to obstruction of visibility and sensitivity of the shear blocks to accidental shear that result in a service call.
- Disclosed herein but not claimed is a personnel lift includes a vehicle chassis, a lifting assembly secured to the vehicle chassis, and a work platform attached to the lifting assembly. The work platform includes a floor structure, a safety rail coupled with the floor structure and defining a personnel work area, and a control panel area. A control box is disposed in the control panel area and includes an operator input implement. Driving components cooperable with the lifting assembly provide for lifting and lowering the work platform. A sensor is positioned adjacent the control panel area and includes a transmitter unit mounted to the safety rail on one side of the control box and a receiver unit mounted to the safety rail on an opposite side of the control box. The transmitter unit emits a light beam across the control panel area to the receiver unit. A control system communicating with the driving components, the control box, and the sensor controls operation of the driving components based on signals from the operator input implement and the sensor.
- Relative to the floor structure, the sensor may be positioned above and in front of the control panel area. The control system may be programmed to shut down the driving components when the light beam from the transmitter unit may be not received by the receiver unit. The control system may be programmed to modify operating parameters of the driving components when the light beam from the transmitter unit is not received by the receiver unit.
- The sensor may include two receiver units that are positioned to receive the light beam from the transmitter unit. In this context, the control system may be programmed to prevent operation of the driving components when one or both of the receiver units do not detect the light beam. Additionally, the control system may be programmed to reverse a last operation by the driving components when one or both of the receiver units do not detect the light beam for a predetermined period of time, which may be at most one second.
- The lift may include an override switch communicating with the control system to permit operation of the driving components at creep speed despite that the receiver unit does not detect the light beam.
- The sensor may include a first housing in which the transmitter unit is disposed and a second housing in which the receiver unit is disposed, where the first and second housings include respective clamps for attaching the housings to the safety rail. A window opening may be provided in each of the first and second housings and a window may be disposed in each of the window openings, where the windows are positioned adjacent the transmitter unit and the receiver unit, respectively. The windows may protrude from a surface of the housings.
- The lift may additionally include a warning system positioned adjacent the control panel area on an operator side of the sensor. The warning system may include a warning transmitter unit mounted on the one side of the control box, a warning receiver unit mounted on the opposite side of the control box, and an indicator lamp. The warning transmitter unit emits a second light beam across the control panel area to the warning receiver unit. In this context, the control system may be programmed to change the indicator lamp when the second light beam from the warning transmitter unit is not received by the warning receiver unit.
- According to a first aspect of the present invention there is provided a system for protecting an operator on an aerial work platform from a crushing hazard, the aerial work platform including a floor structure, a safety rail coupled with the floor structure and defining a personnel work area, and a control panel area, the system comprising a sensor positionable adjacent the control panel area, the sensor including a first transmitter unit positioned on one side of the control panel area and a first receiver unit positioned on an opposite side of the control panel area, the first transmitter unit emitting a light beam across the control panel area to the first receiver unit, the system further comprising a control system communicating with the sensor and cooperable with driving components of the aerial work platform, the control system being programmed to control operation of the driving components based on signals from the sensor, the sensor comprising a housing for each of the first transmitter unit and the first receiver unit, the housings being attachable to the safety rail, and wherein the sensor further comprises a warning system including: a second transmitter unit disposed in one of the housings; a second receiver unit disposed in the other of the housings, wherein the second transmitter unit and the second receiver unit are positioned on an operator side of the first transmitter unit and the first receiver unit, respectively; and an indicator lamp, wherein the second transmitter unit emits a second light beam across the control panel area to the second receiver unit, and wherein the control system is programmed to change the indicator lamp when the second light beam from the second transmitter unit is not received by the second receiver unit.
- Also disclosed but not claimed is a personnel lift including a vehicle chassis, a lifting assembly secured to the vehicle chassis, and a work platform attached to the lifting assembly. A control box is disposed in the control panel area and includes an operator input implement. Driving components cooperable with the lifting assembly lift and lower the work platform. An opto-electric sensor positioned adjacent the control panel area is configured to detect an object entering the control panel area. A control system communicating with the driving components, the control box, and the sensor controls operation of the driving components based on signals from the operator input implement and the sensor.
- These and other aspects and advantages will be described in detail with reference to the accompanying drawings, in which:
-
FIG. 1 illustrates an exemplary lift vehicle; -
FIGS. 2-3 show a work platform including a protection envelope of a first embodiment; -
FIG. 4 shows a control panel area and a protective envelope including a platform switch; -
FIG. 5 is a cross-sectional view of the platform switch; -
FIGS. 6-7 show an alternative design of the protection envelope including the platform switch; -
FIG. 8 shows the platform switch connected with shear elements; -
FIG. 9 is a perspective view showing an alternative platform design including the switch bar and platform switch; -
FIG. 10 is a detailed view of the switch bar and platform switch secured to the platform ofFIG. 9 ; -
FIG. 11 is a close-up view of the switch bar secured to a sensor support bar of the platform shown inFIG. 9 ; -
FIGS. 12 and 13 are perspective views of a work platform incorporating an opto-electric sensor system; -
FIG. 14 is a section view of a sensor housing; -
FIG. 15 is a perspective view of the opto-electric sensor system incorporating an extra transmitter/receiver pair; and -
FIG. 16 shows an alternative embodiment with the sensors integrated with the platform control box. -
FIG. 1 illustrates an exemplary typical aerial lift vehicle including avehicle chassis 2 supported on vehicle wheels 4. A turntable and counterweight 6 are secured for rotation on thechassis 2, and an extendible boom assembly is pivotably attached at one end to the turntable 6. Anaerial work platform 10 is attached at an opposite end of theextendible boom 8. The illustrated lift vehicle is of the self-propelled type and thus also includes a driving/control system (illustrated schematically inFIG. 1 at 12 ) and acontrol console 14 on theplatform 10 with various control elements that may be manipulated by the operator to control such functions as boom angle, boom extension, rotation of the boom and/or platform on a vertical axis, and engine, steering and braking controls, etc. -
FIGS. 2 and3 show anexemplary work platform 10 including a protection envelope according to a first embodiment of the invention. Theplatform 10 includes afloor structure 20, asafety rail 22 coupled with thefloor structure 20 and defining a personnel work area, and acontrol panel area 24 in which thecontrol panel 14 is mounted. The protection envelope surrounds thecontrol panel area 24 and serves to enhance protection for the operator from an obstruction or structure that may constitute a crushing hazard. - As shown in
FIGS. 2 and3 , the protection envelope may include protection bars 26 on either side of thecontrol panel area 24 extending above thesafety rail 22. Thesafety rail 22 includes side sections (the longer sections inFigs. 2 and3 ) and end sections (the shorter sections inFigs. 2 and3 ). Thecontrol panel area 24 may be positioned within one of the side sections. In one construction, the protection bars 26 are disposed intermediately within the one of the side sections adjacent thecontrol panel area 24. In an alternative construction, the protection bars 26 may be disposed in alignment with the end sections of the safety rail 22 (as shown in dashed line inFIG. 3 ). Preferably, the protection bars 26 extend above thesafety rail 22 by an amount sufficient to accommodate an anteroposterior diameter of an adult human (i.e., a distance between a person's front and back). In this manner, if an obstacle is encountered that could result in crushing the operator between the structure and thecontrol panel 14, the operator will be protected from injury by the protection bars 26 with sufficient space between thecontrol panel 14 and a top of the protection bars 26 to accommodate the operator's torso.FIG. 3 shows the user in a "safe" position where an encountered structure is prevented from crushing the operator by the protection bars 26. - An alternative protection envelope is shown in
FIG. 4 . In this embodiment, the protection envelope includes aswitch bar 28 secured in thecontrol panel area 24. Aplatform switch 30 is attached to theswitch bar 28 and includes sensors for detecting the application of a force, such as by an operator being pressed into the platform switch by an obstruction or structure. Theplatform switch 30 is configured to trip upon an application of a predetermined force. The force causing theplatform switch 30 to be tripped may be applied to theplatform switch 30 itself or to theswitch bar 28 or to both. It has been discovered that inadvertent tripping can be avoided if the predetermined force is about 40-50 lbs over a 6" sensor (i.e., about 6.5-8.5 lbs/in). As shown, theswitch bar 28 and theplatform switch 30 are positioned between the personnel work area and thesafety rail 22. Relative to the floor structure, theswitch bar 28 and theplatform switch 30 are positioned above and in front of thecontrol panel area 24. Based on an ergonomic study, it was discovered that theswitch bar 28 andplatform switch 30 should be positioned about 50" above the platform floor. - Although any suitable construction of the
platform switch 30 could be used, a cross section of anexemplary switch 30 is shown inFIG. 5 . Theswitch 30 includes aswitch housing 32 with internal ribs 34 connected between the switch housing and apressure switch 36. Sensitivity can be adjusted by selecting a differentrating pressure switch 36 and/or by adjusting the number, shape and stiffness of the ribs 34. Theswitch bar 28 andplatform switch 30 also serve as a handle bar that an operator can grab in an emergency. - An alternative
platform switch assembly 301 is shown inFigs. 6 and7 . Theswitch assembly 301 includes aplatform switch 302 with injection moldedend caps 303 and diecast mounting brackets 304. Theplatform switch 302 operates in a similar manner to theswitch 30 shown inFIGS. 4 and5 . An exemplary suitable switch for the platform switch is available from Tapeswitch Corporation of Farmingdale, NY. - With reference to
FIG. 8 , theplatform switch bar 28 may be secured to thecontrol panel area 24 via ashear element 38. Theshear element 38 includes a reduced diameter section as shown that is sized to fail upon an application of a predetermined force. With this construction, in the event that the machine momentum or the like carries the platform beyond a stop position after the platform switch is tripped, theshear elements 38 will fail/break to give the operator additional room to avoid entrapment. The predetermined force at which theshear element 38 would fail is higher than the force required to trip theplatform switch shear element 38, since nylon has low relative elongation to plastic. Of course, other materials may be suitable. - In use, the driving components of the vehicle that are cooperable with the lifting assembly for lifting and lowering the work platform are controlled by an operator input implement on the
control panel 14 and by the driving/control system 12 communicating with the driving components and thecontrol panel 14. Thecontrol system 12 also receives a signal from theplatform switch platform switch control system 12 is programmed to shut down driving components when theplatform switch control system 12 may reverse the last operation when theplatform switch - If function cutout is selected, when the platform switch is tripped, the active function will be stopped immediately, and all non-active functions shall not be activated. If a reversal function is selected, when the platform sensor is tripped during operation, the operation required RPM target is maintained, and the active function only when the trip occurred is reversed until the reversal function is stopped. A ground horn and a platform horn can be activated when the reversal function is active. After the reversal function is completed, engine RPM is set to low, and all functions are disabled until the functions are re-engaged with the foot switch and operator controls. The system may include a platform switch override button that is used to override the function cut out initiated by the platform switch. If the override button is pressed and held, it enables the hydraulic functions if the foot switch and controls are re-engaged sequentially. In this event, function speed is set in creep mode speed automatically. The controller is programmed to avoid the cut out feature being disabled before the platform switch is tripped regardless of whether the override button is pressed or released. This assures that the cut out feature will still be available if the override button is stuck or manipulated into an always-closed position.
- The reversal function is implemented for various operating parameters of the machine. For vehicle drive, if drive orientation shows that the boom is between the two rear wheels, reversal is allowed only when the drive backward is active and the platform switch is tripped. If a drive forward request is received when the platform switch is tripped, it is treated as a bump or obstacle in the road and will not trigger the reversal function. If the drive orientation shows that the boom is not in line with the rear wheels, then both drive forward and drive backward may trigger the reversal function. Additional operating parameters that are implemented with the reversal function include main lift, tower lift, main telescope (e.g., telescope out only), and swing.
- Reversal function terminates based on the platform switch signal, footswitch signal and time parameters that are set for different functions, respectively. If the platform switch changes from trip status to non-trip status before the maximum reversal time is elapsed, then the reversal function will be stopped; otherwise, the reversal function is active until the maximum reversal time is elapsed.
- Disengaging the footswitch also terminates the reversal function at any time.
- If an operator is trapped on the platform, ground control can be accessed from the ground via a switch. In the ground control mode, if the platform switch is engaged, boom operation is allowed to operate in creep speed. If the platform switch changes status from engaged to disengaged, then operation is maintained in creep speed unless the ground enable and function control switch is re-engaged.
-
FIGS. 9-11 show analternative work platform 110 including afloor structure 120, asafety rail 122 coupled with thefloor structure 120, and acontrol panel area 124 to which the control panel (not shown) is mounted. Theswitch bar 28 andplatform switch 30 are secured in thecontrol panel area 124. Thecontrol panel area 124 includes asensor support bar 126 having atop crossbar 128 extending along a width dimension (W inFIG. 9 ) andsidebars 130 extending substantially perpendicularly from thetop crossbar 128. Thesidebars 130 define a width of thecontrol panel area 124. - The
sensor support bar 126 is preferably bent from a single piece of material, although multiple pieces can be attached to one another in the arrangement shown. Each of thesidebars 130 may include an upper section extending from the top crossbar inward in a depth dimension (D inFIG. 9 ) to a bent section. A lower section preferably extends from the bent section outward in the depth dimension to thesafety rail 122. With continued reference toFIG. 9 , the upper section of thesidebars 130 may be angled downwardly from thetop crossbar 128 to the bent section. The lower section may extend at an angle from the bent section to thesafety rail 122. As shown, the lower section may extend in a substantially straight line from the bent section to the safety rail. In the arrangement shown, thesafety rail 122 extends above thefloor structure 120 to a rail height, where the lower sections of thesidebars 130 connect to thesafety rail 122 at a position about halfway between thefloor structure 120 and the rail height. AS also shown inFIG. 9 , thetop crossbar 128 is preferably positioned above the rail height. - The
switch bar 28 and theplatform switch 30 may be connected to thesensor support bar 126 at the bent sections of thesidebars 130 as shown. The platform switch is positioned inward in the depth dimension D of the floor structure such that an operator in the control panel area is closer to theplatform switch 30 than to thesafety rail 122. Preferably, the switch bar and platform switch are under-mounted on thesensor support bar 126 relative to an operator standing on thefloor structure 120. That is, as shown inFIGS. 10 and11 , theswitch bar 28 is preferably coupled to an outside surface of thesensor support bar 126 on an opposite side of thesensor support bar 126 relative to a position of an operator standing on the platform. The under-mounted configuration results in a simpler assembly (e.g., without brackets 304) and improved ergonomics. -
FIG. 11 is a close-up view of theswitch bar 30 secured to thesensor support bar 126. In a preferred construction, ablock 132 is fixed (e.g., by welding) to thesensor support bar 126, and ablock holder 134 is fixed (e.g., by welding) to theblock 132. Theblock holder 134 receives ashear block 136 of theswitch bar 30 and is secured by afastener 138 such as a bolt or the like. A similar bolt (not shown) secures theswitch bar 30 to theshear block 136. -
FIGS. 12-14 show another alternative embodiment, which utilizes an opto-electric sensor for detecting an object such as an operator entering thecontrol panel area 124. Like previous embodiments, the personnel lift includes a vehicle chassis, a lifting assembly secured to the vehicle chassis, and a work platform attached to the lifting assembly. The work platform includes a floor structure, asafety rail 122 coupled with the floor structure and defining a personnel work area, and a control panel area. See, for example,FIGS. 1-3 and9 . A control panel orcontrol box 14 is disposed in thecontrol panel area 124 and includes one or moreoperator input elements 125. Like previously described embodiments, driving components are cooperable with the lifting assembly for lifting and lowering the work platform. - With reference to
FIGS. 12 and 13 , asensor 402 is positioned adjacent thecontrol panel area 124. Relative to the floor structure 20 (seeFIGS. 2 ,3 and9 ), thesensor 402 is positioned above and in front of the control panel area. Thesensor 402 includes atransmitter unit 404 mounted to aside bar 130 of thesafety rail 122 on one side of thecontrol box 14 and areceiver unit 406 mounted to aside bar 130 of thesafety rail 122 on an opposite side of thecontrol box 14. Thetransmitter unit 404 emits a light beam across thecontrol panel area 124 to thereceiver unit 406. The control system 12 (shown schematically inFIG. 1 ) communicates with the driving components, thecontrol box 14 and thesensor 402. Thecontrol system 12 controls operation of the driving components based on signals from the operator input element(s) 125 and thesensor 402. - In some embodiments, the
receiver unit 406 is actually two receiver units that are both positioned to receive the light beam emitted from the transmitter unit 404 (seeFIG. 14 ). In use, if the light beam from thetransmitter unit 404 is detected by the receiver unit 406 (or both receiver units in the embodiment where tworeceiver units 406 are provided), the machine is allowed to operate normally. If the receiver unit 406 (or either or bothreceiver units 406 in the embodiment utilizing two receiver units) does not detect the transmitter beam (such as if the operator leans over the platform control box 14), the control system is programmed to stop machine functions, and further operation from the platform is prevented. Additionally, the control system may be programmed to reverse a last operation by the driving components when one or both of thereceiver units 406 do not detect the light beam for a predetermined period of time, which at most may be one second or less. - Like previously described embodiments, the system may include an override switch on the
platform control box 14 to allow function use at reduced (creep) speed. Normal operation of the machine is prevented until the receiver unit 406 (or both receiver units 406) detect the transmitter beam. - With continued reference to
FIGS. 12 and 13 , thesensor 402 may include ahousing 408 in which thetransmitter unit 404 is disposed and ahousing 410 in which the one ormore receiver units 406 are disposed (see alsoFIG. 14 ). The housings includerespective clamps 412 for securing the housings to the side bars 130 of thesafety rail 122. In some embodiments, the housings include awindow opening 414 and awindow 416 disposed in each of thewindow openings 414. Thewindows 416 are positioned adjacent thetransmitter unit 404 and the receiver unit(s) 406, respectively. In some embodiments, thewindows 416 protrude outward of the housing surface to facilitate cleaning (e.g., scraping paint, removing dirt, concrete spray, etc.). -
FIG. 15 shows a modified sensor system incorporating an extra transmitter/receiver pair 418 as part of a warning or teaching system. That is, the extra transmitter/receiver pair 418 communicates the status of the system to the operator and teaches the operator of the location in which the sensor is active. The additional transmitter/receiver pair 418 is positioned adjacent thecontrol panel area 124 on an operator side of thesensor 402. Specifically, the transmitter/receiver pair 418 includes a warning transmitter unit mounted on one side of thecontrol box 14, a warning receiver unit mounted on the opposite side of thecontrol box 14, and anindicator lamp 420. The warning transmitter unit emits a second light beam across thecontrol panel area 124 to the warning receiver unit, and the control system is programmed to change theindicator lamp 420 when the second light beam from the warning transmitter unit is not received by the warning receiver unit. When the warning beam is interrupted, the indicator lamp 420 (or set of lamps) is changed, either turned off or changed from one color to another such as green to red. The indicator light or lights provide the operator with information that the system is ready and functioning and help the operator to develop proper habits, e.g., teaching the operator to remain in the proper position relative to the control box to facilitate smooth and uninterrupted operation of the machine. - In some embodiments, when power is applied to the machine control system, the control system may perform a diagnostic check of the receiver and transmitter system. The control system applies power in a predetermined orderly way to the receiver unit(s) and transmitter unit(s). The output values of the receiver units are evaluated by the control system for each powered state in order to detect faults with the components and/or wiring. For a system with two receivers and one transmitter, for example, the possible states are:
R1 R2 T1 OFF OFF OFF OFF ON OFF ON ON OFF ON OFF OFF ON OFF ON OFF OFF ON OFF ON ON ON ON ON - In some embodiments, the sensor may be integrated with the
platform control box 14 as shown inFIG. 16 . As shown, thesensor 4021 is positioned above and in front of the control panel area and is integrated with thecontrol box 14. Thesensor 4021 includes atransmitter unit 4041 on one side of thecontrol box 14 and areceiver unit 4061 on an opposite side of thecontrol box 14. Thetransmitter unit 4041 emits alight beam 4022 across the control panel area to thereceiver unit 4061. The remaining operation is the same as that in the previously described embodiments. - The sensors are preferably industrial photoelectric "light barrier" type sensors, where light and/or reference to a "light beam" is understood to cover a wide range of wavelengths - visible, infrared, laser, etc. The system may utilize receiver units with two complementary outputs. The complementary outputs are monitored in order to detect possible faults in components and wiring. The system may include a dedicated control module for operation and control of the transmitter, receiver and status lights (if any) including a machine platform control module interface. The dedicated control module may also perform diagnostics on the transmitter unit and the receiver unit(s). The sensor may include two discrete receiver units to provide redundancy. The sensor may include two discrete transmitter units and two discrete receiver units. Still further, the sensor may include a single transmitter unit and two discrete receiver units.
- It is to be understood that the invention is not to be limited to the disclosed embodiments, and may cover various modifications, within the scope of the appended claims.
Claims (1)
- A system for protecting an operator on an aerial work platform (10) from a crushing hazard, the aerial work platform (10) including a floor structure (20), a safety rail (122) coupled with the floor structure (20) and defining a personnel work area, and a control panel area (124), the system comprising a sensor (402) positionable adjacent the control panel area (124), the sensor (402) including a first transmitter unit (404) positioned on one side of the control panel area (124) and a first receiver unit (406) positioned on an opposite side of the control panel area (124), the first transmitter unit (404) emitting a light beam across the control panel area (124) to the first receiver unit (406), the system further comprising a control system (12) communicating with the sensor (402) and cooperable with driving components of the aerial work platform (10), the control system (12) being programmed to control operation of the driving components based on signals from the sensor (402), wherein the sensor (402) comprises a housing (408; 410) for each of the first transmitter unit (404) and the first receiver unit (406), the housings (408; 410) being attachable to the safety rail (122), and
wherein the sensor (402) further comprises a warning system including:a second transmitter unit disposed in one of the housings;a second receiver unit disposed in the other of the housings, wherein the second transmitter unit and the second receiver unit are positioned on an operator side of the first transmitter unit (404) and the first receiver unit (406), respectively; andan indicator lamp (420), wherein the second transmitter unit emits a second light beam across the control panel area (124) to the second receiver unit, and wherein the control system (12) is programmed to change the indicator lamp (420) when the second light beam from the second transmitter unit is not received by the second receiver unit.
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US15/094,286 US10124999B2 (en) | 2010-12-20 | 2016-04-08 | Opto-electric system of enhanced operator control station protection |
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JP (1) | JP6397954B2 (en) |
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JP6397954B2 (en) | 2018-09-26 |
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