Abstract:
A laser lighting assembly, mounted on a forklift, will be projecting a light beam parallel to and in the same plane as a fork, which itself is parallel to a floor or ground level. Until the forks are parallel to the floor or ground level the laser light will not be continuously on. When an operator of the forklift is adjusting the forks to be level, and then parallel to the floor or ground level, as the level positions are being approached, the laser light appears in a blinking sequence with the off periods initially being longer and then becoming shorter as the level positions are approached. Then when the level positions of the forks are reached the laser light is on full time. In addition, a laser light beam is provided which projects as a planar beam of light to match the planar location of both of the projecting forks of the forklift, and the operator then, if necessary, adjusts his or her controls of the forklift to insure the forks will also be in the same planar location of the fork receiving volume of the loaded pallet while remaining parallel to the floor or ground level.

Description:
CROSS REFERENCE 
     This application is a cross reference to, and incorporates the information set forth in the application Ser. No. 09/151,479, filed by Forrest D. Sower and Matthew Scott Sower, on Sep. 9, 1998, and entitled, LASER LIGHTING ASSEMBLY MOUNTED ON A FORKLIFT. 
    
    
     BACKGROUND 
     The laser lighting assembly mounted on a forklift to project a light beam parallel to and in the same plane as a fork, which is used to accurately direct the fork into a fork receiving volume of a pallet, as illustrated and described in U.S. patent application Ser. No. 09/151,479, is successfully being used to avoid fork damage to a load supported on a pallet. During these period of such successful use, some of those persons who operate the forklift, supervise such operations, and/or have the responsibility over the overall businesses involved, have suggested new requirements they would like to have considered, to improve the advantages to be gained by mounting and operating the laser lighting assembly on a forklift. 
     SUMMARY 
     To meet suggestions, requests, and/or demands, improvements to the laser lighting of assembly, in conjunction with other components and related circuitry, are now provided to increase the overall controls and effectiveness of utilizing a laser lighting assembly mounted on a forklift, as shown in the drawings and described in the specification of this application, in comparison with the disclosure in the previous application Ser. No. 09/151,479. 
     An eye flash from the laser used, known as a class III A Laser, is understood not to be a possible cause of a person&#39;s eye damage. Yet to eliminate this perception of such a possible injury, and/or to avoid a nearby worker being startled by a laser flash, possibly causing him or her to have an accident,ran improvement is provided, whereby the laser lighting assembly is automatically controlled only to be on, when a selected pallet fork receiving volume is located at least a given height above floor or ground level. 
     Currently, the selected height is seven feet, and the selected way of providing this improvement, utilizes infrared waves emitting and receiving equipment mounted at different locales on the forklift. The emitter is adjusted to be effective in a volume above seven feet. Therefore, until the receiver reaches the seven foot level, the laser lighting assembly, via circuitry configurations, will be inactive until the receiver arrives at the seven foot level. Then the receiver becomes active at this level and higher levels served by operating a designated forklit, and the laser lighting assembly is tuned on. 
     Where these possible concerns are not thought to be necessary at anytime this improvement may not be wanted, and the laser lighting assembly will be on at all levels. 
     However, when a forklift is to be operated, where these concerns are important most of the time, yet, with precautions, the observance of the reflected laser light beam must be observed at lower levels by an operator, then an overriding control is provided to turn on the laser lighting assembly when operations are undertaken below the selected foot level, which generally is the seven foot level. 
     In respect to the best positioning of the forks, beyond the correct level of the tips of the forks, there is the need to horizontally position the entire length of each one of the forks. Therefore an another added component, and it&#39;s circuitry are utilized to control the on time of the laser lighting assembly, so a laser light beam will only be created and be observable by the operator, when the entire lengths of both forks are horizontal, and parallel to a floor or a ground level. Until the forks are parallel to a floor or a ground level the laser light will not be continuously on. When an operator of the forklift is adjusting to a floor or ground level, and then parallel to a floor or ground level, as the level positions are being approached, the laser light appears in a blinking sequence with the off periods initially being longer and then becoming shorter as the level positions are approached. Then when the level positions of the forks are reached the laser light is on full time. 
     Yet still at this adjustment period, each fork, although being horizontal, may not be in the same horizontal plane with the other fork. Therefore to further assist the operator of a forklift so he or she may be very sure that the forks will correctly enter the fork receiving volume of a pallet, a laser lighting assembly is designed to project a planar beam of laser light, which appears, when reflected, as a line beam of laser light. This planar beam is of a sufficient line length to let the operator know when he or she has, as necessary, further adjusted the level of the forks tips of the level forks, so they are both in the same horizontal plane. Then when this horizontally. lined beam of laser light disappears at the fork receiving volume of the pallet, the operator of the forklift is further assured, the forks, which are horizontally level and in the same horizontal plane, will perfectly enter the forks receiving volume of the pallet, and no product or products loaded on the pallet will be damaged by the forward movement of the forklift to place the forks into their lifting positions in the fork receiving volume of a pallet. 
     At all times, the operator of a forklift may turn a master on-off switch to the selected position Then, in addition, timing apparatus and circuitry is provided, so when the master switch has been left on, but the forklift has not been maneuvered during a preset time, the laser lighting assembly will be automatically shut off, and battery energy will be preserved. 
    
    
     DRAWINGS 
     The improved laser lighting assembly mounted on a forklift to project a light beam parallel to and in the same plane as a fork, and utilized to accurately direct forks into a receiving volume of a pallet, thereby avoiding any fork damage to a load on a pallet is illustrated in the drawings, wherein: 
     FIG. 1 is a perspective view of a forklift approaching a column arrangement of loads arranged on respective pallets, indicating at this lower level of the forks, the light beam is not being created, to avoid startling person walking nearby, and to avoid any of their concerns about their unintentional viewing of the strong light beam, such as a laser light beam; 
     FIG. 2 is perspective view, like FIG. 1, of a forklift approaching a column arrangement of a forklift loads arranged on respective pallets, and the forks have been raised sufficiently high that the reflections of the light beam on the loads are observable to the operator, yet when the light beam reaches the fork receiving volume of a pallet, the reflection disappears, indicating to an operator that the forks are at the correct level to be advanced into the fork receiving volume, and thereby avoiding any possible damage to the load, 
     FIG. 3 is a schematic side view, with some portions removed, of a forklift approaching a column arrangement of loads arranged on respective pallets and the phantom lines indicate the forks at respective raised positions, and at the lower position the light beam has not been created to avoid having a person walking nearby being startled or concerned about viewing a strong light beam, such as a laser light beam, and at the higher position the light beam is active and creating a reflection on a load of observation by the operator, and this light beam has been activated when an infra-red generator/emitter&#39;s infra-red ray energy emitted from a high frame level location on the forklift is being received by an infra-red receiving module which is on raised vertical portions of a forklift that support the forks of the forklift, and through such transmission and receiving of infra-red wave energy, a switch is automatically turned on, until the infrared wave energy is no longer receivable at lower  8  elevations of the infra-red receiving module being lowered, when the forks are being lowered; 
     FIG. 4 is a side view of a second housing which contains many components, including circuitry, switches, and the infra-red receiving module, and as noted in FIG. 3, this second housing is secured on the backside of the upright, i.e. vertical, portions of a forklift that support the forks of the forklift; 
     FIG. 5 is a partial perspective view looking up to the second housing to observe where the infra-red receiving module receives the infra-red energy, to observe side location of portions of switch to be manipulated, to observe indicating lights, and to observe circuit connector receiving locations; 
     FIG. 6 is a perspective view of the infra-red generator/emitter; 
     FIG. 7 is a partial perspective view showing a selected protective location on a forklift where the second housing is secured on the backside of the upright, i.e. vertical, portions of a forklift that support the forks of the forklift; 
     FIG. 8 is a partial perspective lower corner view, of a forklift again showing a selected protective location of the second housing, and then showing the reasonably protective location of the first housing containing the light beam, i.e. laser light beam, creating unit, on an inside side location of the horizontal fork at the location of the base of the upright, i.e. vertical, portion of a forklift, and also showing the expandable length of the circuit wires extending between the first and second housing locations, and portions of these circuit wires are protected within a conduit which is secured to the upright, i.e. vertical portion of the forklift that supports a fork of the forklift; 
     FIG. 9 is a partial perspective lower front view of a forklift again showing a selective protective location of the second housing, the expandable length of the circuit wires extending between the first and second housing locations, and portions of these circuit wires are protected within a conduit which is secured to the upright, i.e. vertical, portion of forklift that supports a fork of the forklift; 
     FIG. 10 is a partial perspective side view of the upright, i.e. vertical, portions of a forklift, which also serve in positioning the load while supporting the forks, and showing the selected protective mounting of the second housing, which when moving up and down with these fork structures, moves through the clearance volume between vertical moving and vertical non-moving portions of a forklift; 
     FIG. 11 is a partial perspective view of the spaced forks of the forklift illustrating the reasonably protective location of the first housing, and showing how a laser light creating unit has been installed in the first housing which produces a planar expanding laser light beam, which upon reaching a load presents a horizontal line reflection for observation of an operator, providing both forks are extending horizontally and both forks are in the same horizontal plane, but if the line reflection is not horizontal, the operator must adjust the positions of the forks until the line reflection is horizontal; 
     FIG. 12 is similar to FIG. 10, and is a partial perspective side view of the upright, i.e. vertical, portions of a forklift which also serve in positioning the load while supporting the forks, and in this view, a third housing is protectively mounted, and as shown the third housing is smaller than the second housing showing in FIG. 10, because the electrical energy source being utilized is the main large battery installed on the forklift, as indicated by the portions of the circuit wires and the note saying to battery, whereas in contrast the second housing is larger to provide for a battery specifically used to provide the source of electrical energy to the laser lighting assembly operating the laser light unit; 
     FIG. 13 is similar to FIG. 11, and is a partial perspective view of the spaced forks of the forklift illustrating how a pre-assembly of a smaller fourth housing, a smaller laser lighting assembly, and a first section of the protective conduit, is pre-positioned by clamps, not shown, and then secured to the upright, i.e. vertical, portion of a fork, preferably by welding; 
     FIG. 14 is an enlarged partial perspective view of portions of the fork and its upright, i.e. vertical, portions showing the. installation of the smaller fourth housing containing the laser light creating unit, and the fourth housing has three access holes for making light alignment adjustments of the laser light creating unit, and also showing how the fourth housing is pre-assembled with the first section of the protective conduit encompassing the circuitry, and how this pre-assembly has been welded to the upright portion of the fork, as previously indicated in FIG. 13; 
     FIG. 15 is a schematic diagram with names, lines, and arrows to illustrate how the components of the laser light assembly interact with one another; and 
     FIGS. 16A and 16B together illustrate schematically, circuitry and connected components to further indicate how the components of the laser light assembly interact with one another. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Introduction 
     Previously in U.S. patent application Ser. No. 09/151,479, a laser lighting assembly  18  was illustrated and described mounted on a forklift  10  to project a laser light beam  20  parallel to and in the same plane as a fork  22 , and utilized by an operator of a forklift  10  so he or she could thereafter accurately direct the forks  22  into a fork receiving volume of a pallet  28  thereby avoiding any fork damage to a load  14 , often arranged with other loads  14  on pallets  28  in a column  12 . The laser light beam  20  reflected on a load  14  as a reflective spot  26 , but disappeared when the laser light beam  20  was directed into the fork receiving volume  28  of a pallet  16 , thereby indicating to the operator that he or she had the fork  22 , on which the laser lighting assembly  18  was mounted, positioned at the proper level to be moved forward into the fork receiving volume  28  of the pallet  10 , during the forward movement of the forklift  10 . 
     This first use period of this laser lighting assembly  18  has been very satisfactory accomplished and has been well received. During this first use period, customers, users, and potential customers, offered suggestions which have resulted in the improvements illustrated and described in this application. 
     The Laser Light Creating Unit is Automatically Only Turned on when the Forks of a Forklift have Reached and Gone Above a PreSelected Level 
     In many areas where forklifts  10  are operated other persons are often walking. Therefore, so they will not be startled by a laser light beam  20  nor concerned with directly viewing a laser light beam  20 , an infra-red wave energy system  46  is included, as illustrated in FIGS. 1,  2 ,  3 ,  5 ,  6 ,  7 ,  15 , and  16 A, to automatically only turn on the laser light creating unit  24 , when the forks  22  reach a pre-set level above a floor or ground level. 
     In FIGS. 3,  6 , and  7 , an infra-red generator/emitter  48  of the infra-red wave energy system  46 , is illustrated as it is by itself, also where it is mounted on an overhead high frame portion  36  of a forklift  10 , and by using phantom lines, where its effective infra-red wave energy volume  49  is. In FIG. 5, the location of the infra-red wave receiving module  50  of the infra-red wave energy system  46  is shown at the bottom  52  of the second housing  54 , which contains many. of the components and circuitry of the directable high intensity light beam of the lighting assembly  18 , also referred to as the laser lighting assembly  18 . 
     The second housing  54  is safely secured to the back  38  of a vertical, i.e. upright, load contacting member  32  which with others, also supports the horizontal forks  22 . As these parts  54 ,  32 , and  22 , move up and down together there is sufficient clearance between them and the non moving vertical track structure  34  of the forklift  10 , to prevent any damage to the second housing, as illustrated in viewing FIG. 3,  4 ,  5 ,  7 ,  10 . 
     The second housing  54  is mounted at a selected height or the back  38  of the upright load contacting member  32 , so when the forks  22  arrive at a pre-selected height, quite often set a seven feet above a floor or ground level, the infra-red receiving module  50 , positioned in the second housing  54 , will be high enough to receive the infra-red wave energy, and thereafter be active within the circuitry and system illustrated in FIGS. 15 and 16A. When active the infrared receiver module  50  transmits electrical energy to a micro-processor or controller  56 , then its switching or distribution functions occur, so the laser light creating unit  24  is turned on. Thereafter, the operator of the forklift  10  is then able to observe reflections on loads, and the disappearances of reflections at the levels of the respective receiving volumes  28  of the respective pallets  16  arranged with respective loads  14  in a column arrangement  12 , as illustrated in FIGS. 1,  2 , and  3 . 
     The Laser Light Creating Unit is Automatically Only Turned on when the Forks of a Forklift Have Been Adjusted to Be Extending Horizontally Parallel to a Floor or Ground Level 
     Even though a tip  30  of a fork is adjusted to be at the proper level for its entry into the fork receiving volume  29  of a pallet  16 , the operator must be assured that each fork  22  is also extending horizontally parallel to a floor or ground level. If a fork  22  entering the fork receiving volume is not sufficiently being near a level position, a pallet  16  and a load  14  thereon is tilted, and the load  14  may slide off the pallet causing damage to the load  14 , and sometimes damages to other nearby loads  14 . 
     Therefore, as illustrated in FIGS. 15,  16 A and  16 B, a tilt control circuit  60  is provided to enable the laser light creating unit  24  to receive electrical energy only when the forks  22  are extending horizontally parallel to a floor or ground level. As indicated in FIG. 15, the micro-processor controller  56 , upon what is occurring in the tilt control circuit  60 , is controlling whether or not electrical energy is being supplied, i.e. switched to the laser lighting assembly. 
     In FIG. 16B the schematic circuitry and electrical components are shown which comprise the tilt control circuit  60 . There is the inclination sensor  62 , and a level offset adjust unit  64  to adjust the range of the offset from a precise horizontal status of the forks  22 . This offset range still insures that a pallet  16  and its load  14  will not be tilted to any degree that might cause the load  14  to slide off a pallet  10  and possibly cause damage to a product or products, and/or injure a person or persons. 
     In viewing FIGS. 16A and 16B, observe the laser line circuitry line representing cooperating functioning of the inclination sensor  62  and the micro-controller  56 , which in FIG. 15 is called the micro-processor controller of logic of operations  56 . 
     Preferably the Laser Light Creating Unit Preliminarily Blinks At Reducing Spaced Intervals when the Forks of a Forklift Are Being Adjusted to Be Extending Horizontally Parallel to a Floor or Ground Level 
     When an operator of a forklift  10  is adjusting the forks  22  to be horizontally level enough, so when the forklift  10  is moved forward and the forks  22  enter the fork receiving volumes  28 , there will not be any tilting of the pallet  16  and the load  14  thereon, preferably he or she will be observing a blinking reflection of the laser light beam  20 . By judging the changing of the lengths of the intervals of the blinking reflection, he or she, will know well the forks  22  are being adjusted to reach the allowable offset range. As the intervals are being shortened, this allowable offset range is being approached. Then when the laser light reflection is observable full time, the positioning of the forks  22  is within the allowable offset range. 
     In FIG. 16B, the symbol used indicates how the inclination sensor  62  which is in the second housing  54  is utilized to provide this blinking of the laser light beam  20 , creating the instructive reflections with their variable intervals. The operator of the forklift  10  when observing the changing lengths of the intervals is able to more quickly adjust the positions of the forks  22  to reach the allowable offset range. 
     When an Operator Has Left a Forklift, without Manually Switching Off the Electrical Power to the Laser Lighting Assembly, Preferably a No Movement Sensor Becomes Effective to Do So. 
     When an operator leaves a forklift  10  without manually switching off the electrical power to the laser lighting assembly  18 , in order to conserve the source of electrical energy in a battery, a no motion sensing circuit  68  becomes effective to automatically switch off the electrical power to the laser lighting assembly  18 , as illustrated in FIG.  15 . The operation of this no motion sensing circuit  68  is particularly useful, when the electrical energy is being supplied by a small batters in the first housing  54 , which contains most of the overall control circuitry and the controlling electrical components. 
     The Operator of the Forklift, when the Forks Are Lowered Near Floor or Ground Level Conveniently Manually Changes a Three Position Switch Contained in the First Housing 
     An operator of the forklift  10 , when he or she lowers the forks  22  is able to position the second housing  54  within his or her convenient reach, as shown by observing FIGS. 3,  4 , and  5 . The three position switch  72  noted on FIG. 16A as the auto/continuous selector and by off, auto, and cont, has a finger contact portion  74  extending out from the side of the second housing  54 , as shown in FIGS. 4 and 5. 
     The operator when commencing his or her use of the forklift  10  may select the automatic setting to get the full benefit of all the potential automatic changes of times when electrical power from a battery will or will not be reaching the laser lighting assembly  18 . Then when she or he will be adjusting the forks below the selected level, which is generally seven feet above a floor or ground level, the continuous setting will be selected. Upon leaving the forklift  10  he or she will move the finger contact portion  74  to the off position of the three position switch. If he or she forgets, the no motion sensing circuit  68  will become effective and save the battery furnished electrical energy. 
     The Source of Electrical energy Via a Battery is Initially Selectable to Be by Removably Installing a Small Battery in the First Housing, or by Extending Circuitry to the Main Battery of a Forklift 
     The second housing  54  illustrated in FIGS. 4,  5 ,  10  is larger and accommodates a removable battery. The third housing  76  illustrated in FIG. 12 is smaller for it does not accommodate a removable, battery. Instead, circuitry  78  is provided to extend to a main battery of a forklift which then provides the electrical energy needed when the laser lighting assembly  18  is turned on. 
     The Removable Installation of the Second Housing for Subsequent Service and Battery Charging 
     When a second housing  54  is provided which is large enough to accommodate a small battery, the is second housing is positioned, by using a hook and loop fastener  78  secured on and in between the second housing  54  and a mounting bracket  80  which is preferably welded to the back  38  of one of the uprights, i.e. one of the vertical load contacting members  32 , which together are supporting the forks  22 . 
     On occasions this second housing  54 , after being disconnected from the circuitry going to the laser light creating unit  24 , will be conveniently removed by unfastening the hook and loop fasteners, and taken to a battery charger for a recharge. As noted in FIG. 4 on the second housing  54  containing many of the circuits and components of the laser lighting assembly  18 , the indicia says continuous auto off, charging, changer, low bat, and laser. Then on the side of the second housing  54 , as shown in FIG. 4, there is: the finger contact portion  74  of the three position switch  72 ; the green light  82  indicating charging; the socket  84  for receiving a charger circuit connector; the red light  86  indicating low battery; and the socket  88  for receiving a laser light creating unit circuit connector. 
     Utilization of a Laser Light Creating Unit which Creates a Laser Light Beam which Creates a Reflection on a Load that Appears As a Line 
     When an operator of a forklift  10  is adjusting the overall positioning of the forks  22  so they are extending horizontally and are also, as a pair, in the same. horizontal plane, all before the forks are located at the level of fork receiving volume  28  of a pallet  16 , preferably a laser light creating unit  24  mounted in a first housing  25  is installed on a fork  22 , which creates a laser light beam  20  that produces a reflection  90  on a load  14 , appearing as a line  90 . For clarity of illustrating, the side of the load  14  is not shown on which the line reflection  90  is being observed, as illustrated in FIG.  11 . 
     The Pre-Assembly of a Portion of a Conduit with a Smaller Fourth Housing, to Later Contain a Smaller Laser Light Creating Unit, the Housing Having Three Recesses for Later Adjusting Three Threaded Positioners of the Laser Light Creating Unit 
     To speed up the installation of a laser lighting assembly  18  on a forklift  10 , a pre-assembly  94  of a portion of a conduit  44  with a smaller fourth housing  96 , is made by welding  98 , as illustrated in FIG.  14 . Then after clamping the pre-assembly  94  in place with clamps, not shown, the final welding  100  is undertaken. 
     Eventually, when all the conduit  44  is welded in place along the vertical load contacting members  32 , part of the circuitry  40  with the smaller laser light creating unit  102  is passed down through the conduit  44 . The balance of the circuitry  40 , with some portions arranged as a coil, are extended with the end connector thereof to the second housing  54 . 
     Then the smaller laser light creating unit  102  is fitted into the interior of the smaller fourth housing  96 , through an entry, not shown. 
     A person installing the laser lighting assembly  18  continues on by moving the finger contact portion  74  of the three position switch  72  to the continuous position, and with the electrical energy available from a battery, the laser light beam  20  is produced. Thereafter, the installer aligns, as necessary, the laser light beam axis  106  to be inline with the extending fork  22 . 
     He or she accomplishes the alignment by observing a reflection of the laser light beam, and then adjusting positioners, not shown, using a hand tool, not shown, alternately passed through a respective threaded recess  104  of two of them which are accessible after the preassembly  94  has been welded in place. The third positioner reached by a third threaded recess  104  has been previously adjusted before the pre-assembly  94  has been welded in place. When the reflection has been moved to a location which indicates the laser light beam axis  106  is in alignment with the extending fork  22 , the installer knows that subsequently when the reflections on a load  14 , disappear, the fork  22  will have been moved to the level of the fork receiving volume  28 . 
     These Improvements to the Overall Laser Lighting Assembly Enhance the Ability of an Operator of a Forklift to Efficiently Move Loaded Pallets without Causing Any Fork Damage to Any Portions of a Load, and when Necessary Keeping the Laser Lighting Assembly Turned Off 
     When an operator is actively moving a forklift  10  to accomplish the moving of loaded pallets  16 , and he or she has been directed not to utilize the laser light beam  20  below a pre-selected level, generally selected as seven feet above floor level, he or she knows that if the three position switch  72  is in the automatic position, the laser light beam  20  will not come on below this level. 
     Also an operator will know, when the three position switch  72  is in the automatic position, the laser light beam  20  will not be turned on unless the forks  22  are extended horizontally to be parallel to a floor or ground level. 
     Then, if by chance, the operator leaves the forklift  10 , without turning the three position switch  72  to the off position, instead leaving it in the automatic position, he or she understands, the no motion sensing circuit  68  becomes active to cut off the electrical energy through the circuitry  40  from a battery  58 . 
     When a laser lighting assembly . 18 , is installed having a laser light creating unit  24  that projects a laser light beam  20 , which upon reflection  90 , as shown in FIG. 11, an operator, while observing the line reflection  90 , is able to adjust the tips  30  of the forks  22  so the forks  22  will both be in the same horizontal plane, as the observed line reflection  90  is then in the same horizontal plane. 
     When the operator must lower the forks. 22  below the pre-selected level, he or she does so until the three position switch  72  is reachable, and the finger contact portion  74  is moved, so the continuous position is reached. This change is preferably undertaken when the forklift  10  has been driven close enough to a location where a loaded pallet  16  is to be moved, so the possibility of a person walking by is very unlikely, who might be concerned by looking at the laser light beam  20 , or being startled by it. 
     Once the lower level operations are concluded, the operator either returns the three position switch to the automatic position if higher level operations are to be undertaken, or returns the three position to the off position if the forklift is not to be used for lifting operations until a later period of time.