Patent Publication Number: US-2023139590-A1

Title: Smart powered industrial vehicle and systems

Description:
BACKGROUND 
     This application claims priority to U.S. Provisional Patent Application No. 63/273,570, filed on Oct. 29, 2021, titled Smart Powered Industrial Vehicle and Systems, the disclosure of which is incorporated here by reference. 
    
    
     BACKGROUND 
     Current fork designs for powered industrial vehicles and material handling equipment, e.g., a forklift, such as those utilized in a warehouse, allow one or more tines of the fork to strike a pallet while the fork is in a tilt position. In this way, many pallets are damaged when the forks on forklift devices strike the pallet, resulting in shorter useful life of the pallet. The width and slight curving of current forklift tips are also unforgiving when the fork hits the side of a pallet pocket, e.g., a fork pocket, potentially causing additional damage. Damage to the structural integrity of pallets increases the risk of damage to the goods and injury for those working in the warehouse. If a damaged pallet is stored in a rack, there is an additional risk that the pallet may fall during unloading. 
     Another characteristic of the forklift is instability. The forklift and its load should be considered a unit having a continually varying center of mass that varies with every movement of the load. A forklift should never negotiate a turn at speed with a raised load, where centrifugal and gravitational forces may combine to cause a disastrous tip-over accident. Forklifts are a critical element of warehouses and distribution centers. It is imperative that these machines be designed for efficient and safe movement. 
     SUMMARY OF DISCLOSURE 
     Various details of the present disclosure are hereinafter summarized to provide a basic understanding. This summary is not an extensive overview of the disclosure and is neither intended to identify certain elements of the disclosure, nor to delineate the scope thereof. Rather, the primary purpose of this summary is to present some concepts of the disclosure in a simplified form prior to the more detailed description that is presented hereinafter. 
     The new design fork allows the fork to gently ride over the lip of the pallet for easier fork pocket entry to help eliminate pallet damage. Thus, the new fork design limits the fork&#39;s ability to damage the fork pocket and extends the pallet life span. 
     Presently disclosed is a tine for a powered industrial vehicle. In an embodiment, the tine includes a bottom surface; a top surface having a first length; a bevel portion having a second length, wherein the bevel portion is to couple the bottom surface and the top surface and wherein the second length is a multiplier of the first length; and a cavity disposed between the bottom surface and a tip formed by a juncture of the bevel portion and the top surface, wherein the cavity is configured to receive at least one sensor. In some embodiments, the multiplier is between 0.10 and 0.20. In some embodiments, the bevel portion is to couple the bottom surface and the top surface in a substantially linear manner. In some embodiments, the bevel portion has a degree of curvature. In some embodiments, an angle of a juncture of the bevel portion and the bottom surface is an obtuse angle, and the angle may be between 140 degrees and 170 degrees, between 155 degrees and 160 degrees, or between 145 degrees and 170 degrees. In some embodiments, a tip formed by a juncture of the bevel portion and the top surface has a first radius in vertical direction and a second radius in a horizontal direction. In some embodiments, the first radius is less than the second radius. In some embodiments, one or more of the first radius and the second radius is a variable radius associated with an ellipsoidal shape. In some embodiments, one or more of the first radius and the second radius is a constant radius associated with a rounded shape. In some embodiments, the first radius is a second multiplier of the second radius, and the second multiplier is no more than ⅓, no more than ¼, or no more than ⅕. In some embodiments, the constant radius is between 0.1 inches to 1 inch or between 0.2 inches to 0.5 inches. In some embodiments, a tip formed by a juncture of the bevel portion and the top surface is substantially trapezoidal in shape in a horizontal direction that is substantially parallel with the top surface. In some embodiments, the tip has a first radius in a vertical direction and a smaller end of the trapezoidal shape has a second radius in the horizontal direction, and wherein the first radius is less than the second radius. In some embodiments, the tine comprises a coating configured to absorb a shock of striking a pallet, and the coating may be a plastic or elastomeric coating. In some embodiments, the coating is approximately 25 millimeters or less. In some embodiments, the cavity is disposed within the bevel portion. In some embodiments, the at least one sensor is coupled to an internal wall of the cavity using one or more fasteners. In some embodiments, the at least one sensor is sealed within the cavity. 
     Also disclosed is a smart fork system for a powered industrial vehicle. In an embodiment, the smart fork system includes a tine comprising at least one cavity, wherein a sensor is disposed within the at least one cavity; and a processor communicatively coupled to the sensor, wherein the processor is to: receive data from the sensor; and in response to the data, control at least one operation of the powered industrial vehicle. In some embodiments, the sensor is configured to detect one or more motions, one or more orientations, one or more impacts, one or more environmental conditions, or a combination thereof. In some embodiments, the sensor is configured to: detect a condition; and in response to the condition, control a switch, wherein the switch is configured to activate or deactivate a circuit or device of the powered industrial vehicle. In some embodiments, the processor is further configured to store the data to a storage device. In some embodiments, the processor is configured to: determine, based on the data, that an impact has occurred; and in response to the determination of the impact, control a forward extension of the tine, a forward movement of the powered industrial vehicle, an alarm, a communication, or a combination thereof. In some embodiments, the system further includes a second sensor coupled to a second component of the smart fork system, and the processor is further configured to: receive a second set of data from the second sensor; and store the first set of data of the first sensor and the second set of data of the second sensor to a storage device. In some embodiments, the processor is configured to: determine, based on the first set of data, the second set of data, or a combination thereof, a location of the powered industrial vehicle within an environment; and control, based on the location, the at least one operation of the powered industrial vehicle. In some embodiments, the at least one operation is a speed of the powered industrial vehicle, a position of the tine, a forward or backward movement of the powered industrial vehicle, a tilt of a mast of the powered industrial vehicle, an alarm or communication system of the powered industrial vehicle, or a combination thereof. In some embodiments, the second component is a second tine, a mast, a frame, a carriage, a counterweight, an overhead guard, a cab, a power source, or an axle. In some embodiments, at least one of the first sensor or the second sensor is a gravity sensor, an accelerometer, a gyroscope, a tilt sensor, a Global Positioning System (GPS) sensor, a position sensor, a proximity sensor, a vibration sensor, a shock and impact sensor, a velocity or speed sensor, a weight or load sensor, an optical sensor, or a force sensor. In some embodiments, at least one of the first sensor or the second sensor is an image sensor, an object detection sensor, or a camera. In some embodiments, at least one of the first sensor or the second sensor is configured to measure a temperature, a humidity, a luminosity, or an atmospheric pressure. 
     Also disclosed is a method for safely operating a powered industrial vehicle. In an embodiment, the method includes determining a location of the powered industrial vehicle; in response to the location indicating a first zone, controlling a first set of operations of the powered industrial vehicle; and in response to the location indicating a second zone, controlling a second set of operations of the powered industrial vehicle. In some embodiments, the second set of operations includes a subset of the first set of operations. In some embodiments, at least one of the first set of operations or the second set of operations includes at least one of activating or deactivating a circuit or device of the powered industrial vehicle, controlling a position of one or more tines of the powered industrial vehicle, controlling a forward or backward movement of the powered industrial vehicle, controlling a speed of the powered industrial vehicle, controlling a tilt of a mast of the powered industrial vehicle, controlling an alarm or a communication system of the powered industrial vehicle, or a combination thereof. In some embodiments, controlling the first set of operations further includes determining a position of the one or more tines, an orientation of the one or more tines, a weight of a load carried by the one or more tines, or a combination thereof; and in response to a determination that the position, the orientation, the weight, or the combination thereof, indicates an unsafe condition, inhibiting the movement of the powered industrial vehicle. In some embodiments, the method further includes reducing a speed of the powered industrial vehicle to inhibit the movement of the powered industrial vehicle; in response to a determination that the position indicates an unsafe condition, modifying the position so that the one or more tines are in a lowered position proximate to the ground or in a raised position that does not obstruct a field of view of an operator of the industrial powered vehicle; and in response to a determination that the orientation indicates an unsafe condition, modifying the orientation so that a tilt of a mast of the powered industrial vehicle is within a specified range of tilt angles. In some embodiments, controlling the first set of operations further includes reducing a speed of the powered industrial vehicle to inhibit the movement of the powered industrial vehicle; in response to a determination that the weight exceeds a specified threshold and a determination that the position exceeds a specified threshold height, modifying the position so that the one or more times are in a lowered position that is below the specified threshold height; and in response to the determination that the weight exceeds the specified threshold and a determination that the orientation is outside a specified range of tilt angles, inhibiting the movement of the powered industrial vehicle. In some embodiments, controlling the second set of operations further includes increasing the speed of the powered industrial vehicle. In some embodiments, controlling the second set of operations further includes reducing the speed of the powered industrial vehicle. In some embodiments, the method further includes determining an environmental condition within the first zone or the second zone; in response to the environmental condition indicating a high obstruction, modifying a position of one or more tines of the powered industrial vehicle; and in response to the environmental condition indicating a turn or a hazardous area, reducing a speed of the powered industrial vehicle, modifying the position of the one or more tines, modifying an orientation of the one or more tines, or a combination thereof. In some embodiments, the method further includes determining a stability of the powered industrial vehicle; determining the first set of operations of the powered industrial vehicle based on the stability; and determining the second set of operations of the powered industrial vehicle based on the stability. In some embodiments, the stability includes one or more of a lateral stability, a longitudinal stability, or a dynamic stability. 
     Also disclosed is an operator interface system for a powered industrial vehicle. In an embodiment, the operator interface system includes one or more sensors coupled to a frame of the powered industrial vehicle; and a processor, wherein the processor is configured to: determine, based on data of the one or more sensors, a rotational position of an operator&#39;s head; and based on the rotational position of the operator&#39;s head, control a drive train, a power system, or a combination thereof, of the powered industrial vehicle. In some embodiments, the processor is configured to inhibit operation of the powered industrial vehicle in response to a determination that the rotational position of the operator&#39;s head is misaligned with a direction of travel of the powered industrial vehicle. In some embodiments, the operator interface system includes a sensing device to be worn by an operator, wherein the sensing device comprises a sensor configured to monitor an awareness of an operator, a health of an operator, a condition of an operator, or a combination thereof. In some embodiments, the sensor is a temperature sensor, a heart rate monitor, a timer, or a combination thereof. In some embodiments, the processor is configured to inhibit operation of the powered industrial vehicle in response to a determination that the sensing device is not worn by the operator. In some embodiments, the one or more sensors is an image sensor. In some embodiments, the processor is configured to: determine, based on the data of the one or more sensors, that an object is in a path of the powered industrial vehicle; and in response to the determination that the object is in the path, alert the operator, inhibit a movement of the powered industrial vehicle, notify a remote person, or a combination thereof. In some embodiments, the processor is configured to store the data of the one or more sensors, actions taken by the operator, or a combination thereof, to a storage device. 
     Also disclosed is an integrated control system for a powered industrial vehicle. In an embodiment, the integrated control system includes a status module for determining a status of at least one operational system of the powered industrial vehicle; and an order module for controlling one or more of the operational systems in response to the status. In some embodiments, the operational systems include at least one of a braking system, a drive system, a lifting system, a lighting system, or a combination thereof. In some embodiments, the status module is configured to receive data from one or more sensors of the powered industrial vehicle. In some embodiments, the one or more sensors are disposed within a cavity of a tine of the powered industrial vehicle, affixed to a frame of the powered industrial vehicle, worn by an operator of the powered industrial vehicle, or a combination thereof. In some embodiments, the order module is configured to inhibit a movement of the powered industrial vehicle in response to the status indicating a condition is unmet. In some embodiments, the condition includes at least one of an unengaged brake pedal of a braking system, an engaged throttle of a drive system, or a combination thereof. In some embodiments, the movement includes at least one of a position of one or more tines of a lifting system, an orientation of the one or more tines of the lifting system, a forward movement of the powered industrial vehicle, a rearward movement of the powered industrial vehicle, or a combination thereof. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following figures are included to illustrate certain aspects of the embodiments, and should not be viewed as exclusive embodiments. The subject matter disclosed is capable of considerable modifications, alterations, combinations, and equivalents in form and function, as will occur to those skilled in the art and having the benefit of this disclosure. 
         FIG.  1    illustrates a forklift. 
         FIG.  2 A  is a side view schematic of an example forklift tine in accordance with the present disclosure. 
         FIG.  2 B  is a top view of the example tine of  FIG.  2 A . 
         FIG.  2 C  is a front view of the example tine of  FIG.  2 A . 
         FIG.  2 D  is a close-up view of the tip of the example tine of  FIG.  2 A . 
         FIG.  3    is a schematic illustration of an example smart fork system in accordance with the present disclosure. 
         FIG.  4    illustrates the stability triangle of a forklift vehicle. 
         FIG.  5 A  illustrates a laterally stable forklift vehicle. 
         FIG.  5 B  illustrates a laterally unstable forklift vehicle. 
         FIG.  6    is a schematic illustration of an example operator interface system in accordance with the present disclosure. 
         FIG.  7    is a schematic illustration of an example operator interface system in accordance with the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     A more complete understanding of the components, processes and apparatuses disclosed herein can be obtained by reference to the accompanying drawings. These figures are merely schematic representations based on convenience and the ease of demonstrating the present disclosure, and are therefore not intended to indicate relative size and dimensions of the devices or components thereof and/or to define or limit the scope of the example embodiments. 
     Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to the particular structure of the embodiments selected for illustration in the drawings and are not intended to define or limit the scope of the disclosure. In the drawings and the following description below, it is to be understood that like numeric designations refer to components of like function. 
     The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. 
     Numerical values in the specification and claims of this application should be understood to include numerical values which are the same when reduced to the same number of significant figures and numerical values which differ from the stated value by less than the experimental error of conventional measurement technique of the type described in the present application to determine the value. 
     All ranges disclosed herein are inclusive of the recited endpoint and independently combinable (for example, the range of “from 2 grams to 10 grams” is inclusive of the endpoints, 2 grams and 10 grams, and all the intermediate values). 
     As used herein, the terms “generally” and “substantially” are intended to encompass structural or numeral modification which do not significantly affect the purpose of the element or number modified by such term. 
     The terms “about” and “approximately” can be used to include any numerical value that can vary without changing the basic function of that value. When used with a range, “about” and “approximately” also disclose the range defined by the absolute values of the two endpoints, e.g. “about 2 to about 4” also discloses the range “from 2 to 4.” Generally, the terms “about” and “approximately” may refer to plus or minus 10% of the indicated number. The a range defined as “between” includes the endpoints of such range. 
       FIG.  1    illustrates a typical powered industrial vehicle, embodied as a forklift  100 . Reference is made to this generalized forklift throughout this disclosure, however it is to be understood that the elements and components described herein may be substituted for similarly functioning components as known in the art. Generally, a forklift  100  is a powered industrial truck used to lift and move materials (“loads”) over short distances. Depending on the size and arrangement (dimensions, shape, and weight) of the load, the load may be carried directly by a forklift, or the load may be placed on a pocketed pallet for which the forklift is configured to engage. Forklifts are rated for loads at a specified maximum weight and a specified forward center of mass. This information is located on a nameplate provided by the manufacturer, and loads should not exceed these specifications. 
     With continued reference to  FIG.  1   , forklifts  100  generally include a frame  102 , which serves as the base of the industrial truck to which a mast  104 , a carriage  105 , a counterweight  106 , an overhead guard  107 , a power source (engine or batteries) and other components are attached. 
     The counterweight  106  is a heavy mass attached to the rear of the forklift truck frame  102 . In electric forklifts, the battery power source may serve as part of the counterweight  106 . The counterweight  106  compensates for the load carried by the forklift  100 . That is, forklifts operate on the principle of a fulcrum where weight on the forks are to be counterbalanced by the counterweight and weight of the forklift. In most forklift designs, the fulcrum is the drive axle. 
     As mentioned, the forklift  100  may also include the mast  104  that does the work of raising and lowering the load and is mounted to the front axle  103  or frame  102  of the forklift. The mast  104  is typically composed of interlocking rails that also provide lateral stability. The interlocking rails may have either rollers or bushings as guides. The mast  104  may be driven hydraulically, and operated by one or more hydraulic cylinders directly or using chains from the cylinders. A carriage  105  is a component to which forks or other attachments mount. The carriage  105  is usually embodied as a substantially flat metal plate that is mounted into and moves up and down the mast  104  by means of chains or by being directly attached to a hydraulic cylinder. Like the mast  104 , the carriage  105  may have either rollers or bushings to guide it in the interlocking mast rails. In addition to raising and lowering the carriage  105 , the mast  104  can be tilted to angle the tines  110  for capturing, supporting and retaining a load. During normal operation the tilt angle of the mast  104  may be limited to a predetermined value set by the manufacturer, the operator, or industry standards. The predetermined tilt angle may limit the movement of the mast to a degree considered appropriate for normal operations in order to prevent excessive tilt or excessive wear and tear on the forklift. For example, in some forklifts the predetermined tilt limit may be 6°. The tilt angle is measured relative to the vertical axis of the forklift. In some embodiments, the presently disclosed system includes a tilt control allowing the mast  104  to be tilted beyond the limit of a predetermined tilt value. For example, the mast  104  may be tilted to an angle of greater than 6°, greater than 9°, or greater than 12°. In some embodiments, the tilt control allows the mast  104  to tilted to a greater angle in order engage a pallet located on a non-level surface or on a surface that is offset from the surface on which the forklift is operated. In one example, a pallet on a trailer may be slightly higher or lower than the floor of a warehouse in which the forklift is operated. In order to engage the pallet on the trailer, a forklift operated on the warehouse floor may need to tilt the mast  104  beyond the normal limit to capture the pallet. In this manner, tines of the forklift may be better aligned with the pallet pocket thereby reducing damage. While allowing the mast  104  to tilt beyond normal limits, the tilt control may still be subject to limits for safety to prevent improper operation of the forklift. In various examples, the maximum tilt allowed by the tilt control may be no more than 10°, no more than 15°, or no more than 25° depending upon the application and the design of the forklift. In yet other embodiments, the tilt control may allow tilting of the mast up to the maximum range of the mast control. 
     The forklift  100  may also include the overhead guard  107  including a metal roof supported by a set of posts at each corner of the cab  108  where an operator may be seated. The overhead guard  107  protects the operator of the forklift  100  from falling objects and other environmental dangers. In some embodiments, the overhead guard is integrated as part of the frame  102 . In some embodiments, the overhead guard comprises a domed structure of clear material, such that the operator has a full field of view when looking upward through the roof/overhead guard, and the overhead guard has a domed contour designed to allow falling objects to deflect outward from the cabin away from the operator. 
     Forklift Tine with Improved Geometry and Sensors 
     In accordance with one aspect of the present disclosure, disclosed is an improved tine for a forklift  100  that reduces potential damage to pallets and materials and provides a platform for incorporating at least one sensor and a “smart fork” system. It is to be appreciated that while the present application is described with reference to forklift tines, it should be appreciated that various aspects of the concept may be applied to other forms of lifting devices. 
       FIGS.  2 A- 2 D  illustrate various views of an example tine  200 , according to one or more embodiments of the present disclosure. The tine  200  may be connected, as a set of two, to the carriage  105  of a forklift  100  for lifting and transporting loads. Each tine  200  is generally L-shaped including a vertically oriented shank  202  that connects the tine  200  to the carriage of a forklift. The connection of the shank to the carriage may be facilitated by mechanical fasteners and/or structures including hooks, pin locks, or any means known in the art to mechanically connect forklift attachments to the forklift carriage. Each tine  200  also includes a blade  204  that is substantially perpendicular to and connected to a bottom of the vertical shank  202  at a heel  206 . 
     The blade  204  has a length L, width W, height H, and a substantially planar top surface  207  and bottom surface  205  opposite the top surface  207 . A bottom surface of a load is configured to rest on and/or engage the top surface  207  of the blade  204 . For example, a set of tines  200  are configured to engage complimentary shaped pockets of a pallet. As the tines  200  are lifted by raising the carriage  105 , the top surface  207  of the blade  204  contacts the top inner surface of the pallet pocket and the pallet is raised under the control of an operator. 
     The length L of the blades are longer than the height H and width W. The front distal end of the blade  204  includes a beveled portion  210  that connects and transitions the bottom surface  205  of the blade to the top surface  207  of the blade. The bevel portion  210  directly reduces the impact from striking the bottom of a container/pallet fork pocket, and further helps the tines to gently ride over a bottom lip of a pallet and enter the fork pocket easier to help reduce pallet damage. In some embodiments, the length P of the beveled portion  210  is about 10% to about 20% of the total length L of the blade. For example and without limitation, a blade  204  having a length L of about 39 inches includes a beveled portion  210  that is about 6 inches in length. In some embodiments and as illustrated in  FIG.  2 A  the beveled portion  210  connects the bottom surface  205  to the top surface  207  in a substantially linear manner. In these embodiments, the angle α created between the bevel portion  210  and bottom surface  205  ranges from about 170 degrees to about 140 degrees. In some further embodiments, the angle α is about 155 to about 160 degrees including about 157 degrees. In some examples, the angle α is about 145 to 170 degrees. Providing the angle α at such measurements will ensure the leading edge of the fork does not strike the base of the fork pocket and thereby extend the useful life of the fork pocket and hence the useful life of the pallet. In other non-illustrated embodiments, the beveled portion  210  connects the bottom surface  205  to the top surface  207  in a non-linear manner, e.g., the beveled portion  210  exhibits some degree of curvature. 
     In some embodiments, a control system for controlling the forks or tines  200  of the forklift  100  may have various tilt settings. For example, a tine/fork control system may have two (2) or more tilt settings, such as the following: (i) a pallet protection setting; and (ii) full tilt setting. In the foregoing example, the pallet protection tilt setting may be operable to restrict the forward tilt such that a degree of tilt angle (e.g., a 5 degree angle) separates the leading end of the fork with a flat surface when tilt is full engaged; which would allow the bottom of the tine  200  to ride over the base of the pallet pocket without hitting the base of the pallet pocket directly, and which would thereby extend the life of the pallet pocket and thus extends the life of the pallet. Also in this example, the full tilt setting may be operable to allow the leading end of the tine  200  to make contact with a flat surface as per normal fork trucks  100 . Where utilized, such a fork control system may be controlled/manipulated via controls (e.g., a switch on the fork truck dashboard within the cab  108 ). 
     The tines  200  may also include a rounded tip  212  at the front most distal end of the blade  204  configured to engage the pocket of a pallet. The round tip  212  is designed to reduce the pallet/container damage when the tip of the blade  204  contacts a surface of the pallet/container outside of its fork pocket. In this way, the tine  200  is more forgiving to a plastic container in case an operator misjudges the fork pocket during the material handing process. 
     The rounded tip  212  is rounded in both the vertical direction (y-axis) and horizontal direction (x-axis). In the horizontal direction, the tip  212  is continuously arcuate at the distal end across the width W of the blade. That is, when viewed from the top, as illustrated in  FIG.  2 B , the tip  212  is substantially convex in a plane substantially parallel with the top surface  210 . In some embodiments and as illustrated, the tip  212  exhibits a constant radius R 1  in the x-z plane across the width W of the blade. For example and without limitation, a 4-inch wide blade has a first tip radius R 1  of about 2 inches. However, it is to be appreciated that the curved tip may also have a variable radius R 1 , such that the resulting top-view profile of the tip  212  is ellipsoidal. Alternatively, the curved tip may be trapezoidal in shape when evaluated in the plane illustrated in  FIG.  2 B . For example, a larger base of the trapezoid may be 100 millimeters (mm) in width and a smaller base of the trapezoid may be 50 mm in width, and with the distance between the smaller and larger bases (e.g., the sides of the trapezoid) being 50 mm. Providing the curved tip with radius R 1  swept back as such softens the entry to the fork pocket to extend the life of the side of the fork pocket and hence the useful life of the pallet. 
     The tip  212  is also rounded in the vertical direction. As illustrated in  FIGS.  2 A and  2 D  the tip  212  is rounded in the vertical direction and connects the beveled portion  210  to the top surface  207 . The vertically rounded tip  212  has a continuous curvature in the y-direction with a radius R 2  that is less than R 1 . In some embodiments, the radius R 2  is constant, exhibiting a semi-circular cross section (see side view of  FIG.  2 D ). The radius R 2  is from about 0.1 inches to about 1 inch. In further embodiments, the radius R 2  is about 0.2 inches to about 0.5 inches, including about 0.250, 0.275, 0.3, 0.325, 0.035, 0.375, 0.4, 0.425, 0.045, and 0.475. In other embodiments, the radius R 2  is variable, exhibiting an ellipsoidal cross-section. In some embodiments, the bevel portion  210  is substantially tangent to the rounded tip  212 . In one example where both R 1  and R 2  are of constant radii, R 2  may be at most ⅓, or ¼, or ⅕ of R 1   
     In some embodiments and with particular reference to  FIG.  2 D , the tine  200  is coated with a plastic or elastomeric coating  225  configured to absorb the shock of hitting a pallet. The coating may be applied by methods known in the art including but not limited to dip coating and spray coating. In some embodiments, only the blade  204  is coated with the coating  225  as the blade  204  and primarily, the tip  212 , come in contact with a load, e.g., a pallet. In some examples, the coating  225  is up to 25 mm thick and can also serve to improve contact with the pallet to prevent pallets from slipping from the fork as may otherwise occur when bare metal forks pick up bare metal pallets. The coating  225  may also act to prevent wear on the fork. For example, oftentimes forks may be disposed of when they reach 10% wear, but providing the coating  225  as described herein may allow for refurbishment of the fork by recoating the surface. An initial coat of a different color to the bottom of the tine  200  may be utilized and act as a wear bar or gauge for notifying the fork owner when the fork needs to be recoated. 
     With reference to  FIGS.  2 A and  2 C , the tine  200  may also include a cavity  220  with an open end  221  of the cavity  220  at a distal portion of the blade  204  and extending toward the heel  206 . In some embodiments and as illustrated, the cavity  220  is located between the rounded tip  212  and bottom surface  205 . In some embodiments, the cavity  220  is located in the beveled portion  210 . The cavity  220  may be positioned within the center of the width W of the blade  204 . However, the central placement of the cavity  220  is not limiting, as the placement of the cavity may be off-center along the width W. The cavity  220  may also be variously embodied, for example and without limitation, as a cylindrical bore having a constant or variable radius R 3 , a rectangular bore, and an irregular shaped hole. 
     With reference to  FIGS.  2 A,  2 C and  3   , the cavity  220  is configured to receive and secure at least one sensor  250  to the blade  204 . The sensor  250  may be held in place by fasteners, and the sensor  250  may be sealed (waterproof) within the cavity  220  and protected by a cover held by side fasteners. Such fasteners may include mechanical fasteners, such as bolts, or mating grooves or snaps, or adhesives, etc. 
     The sensor  250  is in communication with a central computer system  301  of the forklift  100  described in greater detail below. The sensor  250  may be a wireless sensor in wireless communication with the central computer system  301  or may be a wired sensor that is hard-wired with the central computer system  301  of the forklift  100 . The sensor  250  is configured to detect, measure, and transmit the movement of the tine in any direction, including but not limited to acceleration, horizontal position, vertical position, tilt, rotation, or a combination thereof. In some embodiments, the sensor  250  is configured to measure impact, e.g., when the tine strikes a portion of a pallet. The data collected by the sensor  250  could be shared with the industry to make a healthier environment by reducing waste due to forklift operation abuse. The data collected may also be shared with OSHA to understand forklift habits during a material handling process. The forklift habits may be specific as to individual forklift operators and/or specific as to a particular type of material handling equipment. 
     In accordance with another aspect of the present disclosure and with reference to  FIG.  3   , at least one tine  200  operatively connected to the forklift  100  may be configured as a “smart fork” system  300 . That is, the at least one tine  200  includes a sensor  250  placed within the cavity  220  for acquiring data related to the environment, position, and functions of the forklift  100  allowing an operator to have greater control of the machine and providing the ability to monitor usage of the forklift  100 . 
     The central computer system  301  is configured to receive data from at least one sensor, e.g., the sensor  250  positioned on the tine or other sensors  350  positioned in other locations on the forklift  100  including but not limited to the tines. In some embodiments, the central computer system  301  may be integrated in the forklift  100  and may also control operation of the forklift  100  and various functions (e.g., raise and lower loads) as well as control and communicate with other forklift systems and components. In some embodiments, the central computer system  301 , or at least a portion of it, may be a system that is separate from the forklift  100  but may connect to and receive operational data from the forklift  100 . For example, the central computer system  301  may be a remote device capable of receiving data from the sensor  250 ,  350  (e.g., the central computer system  301  may be a tablet or mobile computing device held by an operator on a job site). 
     The central computer system  301  may be variously embodied, without departing from the scope of the present disclosure, as an industrial computer  303 , a personal computer, a tablet, a smartphone or other known device that hosts a software platform and/or application, and/or combinations thereof. The central computer system  301  includes a processor  302  that may be any of various commercially available processors. The processor  302  may be variously embodied, such as by a single-core processor, a dual-core processor (or more generally by a multiple-core processor), a digital processor and cooperating math coprocessor, a digital controller, or the like. The central computer system  301  also includes at least one user interface  304  and/or display configured to present sensor obtained data and execute related functions. The user interface  304  also allows a user to input commands into the central computer system  301  for monitoring and controlling the various components of forklift. In some embodiments, the central computer system  301  is in communication with a control panel  305  of the forklift  100 , wherein the control panel  305  may control the forklift  100  and facilitate user input into the computer system  301 . The central computer system  301  may also include a non-transitory storage medium  307 . The non-transitory storage medium  307  may comprise a hard disk drive, a redundant array of independent disks (e.g., RAID array) or other magnetic storage medium; a solid state drive (SSD), flash memory or other electronic storage medium; an optical disk or other optical storage medium; various combinations thereof, and/or so forth. As mentioned briefly before, data collected by the sensor  250 ,  350  could be saved to the storage medium  307  and later shared with the industry or OSHA. 
     It will be appreciated that the central computer system  301  may be connected to a LAN (Local Area Network) and include any hardware, software, or combinations thereof, capable of implementing the systems and methods described herein. Suitable examples of such hardware include, for example and without limitation, processors, hard disk drives, volatile and non-volatile memory, a system bus, user interface components, display components, and the like. It will further be appreciated that multiple such devices may be used as the central computer  301  in accordance with the subject disclosure. The central computer system  301  may also include a computer communication interface  310  for communicating (wired or wirelessly) with a plurality of devices, including but not limited to the sensors  250 ,  350 , to the forklift control panel  305 , and/or to one or more remote devices such as a server  320 . 
     Each sensor  250 ,  350  may include a communication interface  251 . The communication interface  251  includes circuitry for transmitting collected sensor data to the central computer system  301  via known methods including but not limited to RF transmission, cellular transmission, satellite transmission, etc. In some embodiments, the communication interface  251  is a plug-and-play type card or other type of memory card having an associated interface processor  252  and interface memory. The interface processor  252  may execute preprogramed application software stored within the interface memory for measuring a physical quantity and communicating such data to the central computer system  301  and/or the server  320  via one or more communications networks. Also, such data may be communicated to the control panel  305  of the forklift  100  and/or one or more other localized data servers in addition to or in lieu of the foregoing. The communication interface  251  may include additional known hardware, for example an antenna, RF transmission means, modem, telephone connectors, Ethernet connectors, broadband connections, DSL connections, etc. for transmitting the position and other data. 
     Various types of sensors may be incorporated within the smart fork system  300 . Thus, the sensors  250 ,  350  may be configured to measure various different parameters or conditions, or various combinations of different parameters or conditions, of the forklift  100 . While the smart fork system  300  is described with reference to a pair of sensors ( 250 ,  350 ), it will be appreciated that more or less than two sensors may be utilized without departing from the present disclosure. Thus, one or more additional sensors may be incorporated in the smart fork system  300  to measure one or more additional parameters or combinations of parameters. The sensors  250 ,  350  may monitor various facets of the forklift  100 , such as the tines  200 , the mast  104 , the frame  102 , the carriage  105 , the counterweight  106 , the overhead guard  107 , the cab  108 , the power source (engine or batteries), etc. 
     By way of non-limiting example, the sensors  250 ,  350  may include a gravity sensor, an accelerometer, a gyroscope, a tilt sensor, a Global Positioning System (GPS) sensor, a position sensor, a proximity sensor, a vibration sensor, a shock and impact sensor, a velocity or speed sensor, a weight or load sensor, a sensor configured to detect one or more motions (and/or orientation) associated with a component of the forklift  100 , and/or any combination thereof. In some embodiments, the sensors  250 ,  350  may include an image sensor, an object detection sensor, and/or a camera. In some embodiments, the sensors  250 ,  350  may include one or more sensors configured to measure ambient environment conditions, such as temperature, humidity, luminosity, atmospheric pressure, etc. In some embodiments, one or more of the sensors are configured as a switch (or integrated with a switch) to activate or deactivate a circuit or device to thereby control one or more functionalities of the forklift  100  based on parameters monitored by the sensors. 
     A gravity sensor is a motion sensor that is configured to measure an orientation with respect to the direction of gravity. The gravity sensor enables the determination of the direction of gravity relative to the sensor, for example, on calculated three-dimensional vectors. The gravity sensor may indicate an orientation, such as a degree of rotation with respect to the direction of gravity of the tine  200 , e.g., when tilted. 
     An accelerometer is a sensor configured to detect a change in velocity during a time period, i.e., an acceleration. A three-axis accelerometer may include multiple motion sensors positioned in the x, y, and z-axis directions. The central computer system  301  may receive accelerometer values measured in the multi-axis directions as vector values. The central computer system  301  may then determine a direction in which the mast  104  and/or the tine  200  is rotated or tilted based on values obtained with respect to the three axes. An accelerometer may also be configured to measure impact or shock, i.e., when a tine  200  strikes a load. Thus, an accelerometer may be configured to measure impact or shock, as well as proper acceleration. Shock and impact sensors are configured to detect instances of sudden impact or severe vibration in order to output a value or, in the case of impact switches, activate or deactivate a circuit or device. 
     A gyroscope is a sensor configured to calculate an angle to which the attached component rotates with respect to an axis. This may be represented as a numerical value. A three-axis gyroscope calculates the degree to which the component rotates with respect to three axes. 
     An image sensor is a sensor configured to capture visual data. Generally, image sensors are embodied as a camera and can capture objects and determine position, rotation, and the like with respect to captured objects. 
     In some embodiments, the sensor  250  is configured to measure impact or shock, e.g., when the tine  200  strikes a portion of a pallet or some other obstacle. Thus, the sensor  250  may be a shock and impact sensor configured to detect instances of sudden impact or severe vibration. The data collected by the sensor  250  and the central computer system  301  could be shared with the industry to make a healthier environment by reducing waste due to forklift operation abuse. The data collected may also be shared with OSHA to understand forklift habits during a material handling process. In some embodiments, the sensor  250  is configured as a shock and impact sensor switch that deactivates or activates at least some functionality of the forklift  100  upon sensing impact. In some embodiments, the central computer system  301  is configured to deactivate or activate at least some functionality of the forklift  100  upon receiving data from the sensor  250  indicative of an impact occurrence. The central computer system  301  and/or the server  320  may govern operation of the tines  200  and/or the forklift  100  after determining that an impact has occurred. For example, further forward extension (reach) of the tines  200  or forward movement of the forklift  100  may be inhibited upon sensing that the tine  200  has impacted a pallet or obstacle; and/or operator notifications or alarms may be sounded or initiated upon sensing impact; and/or an instruction sequence may be communicated to the operator upon sensing impact; and/or impact notification may be sent to some central monitoring station in charge of the various operators. The data thus collected and recorded may be used for various purposes, for example, including but not limited to (a) statistical analysis to compare impacts versus locations versus operators to enhance driver training, to flag non-conformance, to improve operational safety efficiency, environment and process design, (b) to be used in any safety or quality investigation, or (c) to be available to outside agencies or insurance providers to show enhanced compliance and to lower insurance rates. 
     In some embodiments, the sensors  250 ,  350  are configured to calculate a speed of either the tine  200  and/or the forklift  100 . In combination with the sensor  250 ,  350  also determining a location of the forklift  100  within a workspace  351 , the central computer system  301  and/or the server  320 , may govern the speed of the forklift  100  in predetermined zones. For example, within workspace  351  are zones  352  and  353 . Zone  353  may be a high foot traffic area and as such, the speed at which a forklift  100  may travel within that zone may be limited, e.g., to 3 miles per hour. When the forklift  100  travels and crosses into zone  352 , the sensors  250 ,  350  detect a change in location and no longer restrict the speed of the forklift  100  to 3 miles per hour. Equally, specific corners, congested areas, cross traffic areas such as intersections, entrances, or exits can also have specific speed restrictions, and the equipment may also govern the speed appropriate to a novice operator, versus an experienced operator, as prescribed by the trainer. In some embodiments, the workspace zones  352 ,  353  may be defined by geo-fencing, i.e., a virtual perimeter for a real-world geographic area. A location-aware sensor may be triggered when it enters or exits a predefined geo-fence. Thus, the smart fork system  300  may control operation of the forklift  100  and/or its components based on a location of the forklift  100 . 
     In particular, the central computer system  301  and/or the server  320  may control operation of the mast  104 , the tines  200 , and/or the forklift  100  based on which workspace zone  352 ,  353  the forklift  100  is currently operating in. In some examples, one or more functions of the forklift  100  (e.g., the motor, the mast  104  and/or the tines  200  thereof) may be activated or deactivated when the forklift  100  enters into a particular zone (e.g., the zone  352 ). For example, when the forklift  100  is determined to be in the (high foot traffic) zone  353 , the central computer system  301  and/or the server  320  may inhibit travel of the forklift  100  unless the tines  200  are safely positioned and oriented (e.g., where the tines  200  are in a lowered position proximate to the ground and/or where the tines  200  are sufficiently high or low to ensure an unobstructed field of view for the operator), and/or unless the mast  104  is safely tilted at an orientation appropriate for the particular zone. In some examples, the central computer system  301  and/or the server  320  may automatically position (move) the mast  104  and/or the tines  200  (or automatically alert/notify the operator to position (move) the same) upon determining that the forklift  100  has crossed into a new zone (e.g., the mast  104  and/or the tines  200  may be automatically moved into a “pedestrian safe” position when the forklift  100  is determined to be in the zone  353 ). In some examples, the forklift  100  is inhibited from entering one or more certain zones if the load carried (supported) by the tines  200  exceeds a certain predetermined threshold weight, and/or if the load carried (supported) by the tines  200  is raised (vertically positioned) above a certain predetermined threshold height, and/or if the mast  104  is tilting the load at a tilt angle that is outside of a certain predetermined range of tilt angles. For example, the central computer system  301  and/or the server  320  inhibit the forklift  100  from entering the zone  353  if it determines that the tines  200  are carrying a load that weighs too much for safe operation in the zone  353 , that is vertically positioned too high for safe operation in the zone  353 , and/or that is tilted at an unsafe tilt angle for safe operation in the zone  353 . As mentioned above, the central computer system  301  and/or the server  320  may automatically position (move) the tines  200  supporting the load to a vertical position that is deemed safe for the zone  353  and/or automatically tilt the mast  104  to a safe tilt angle upon determining that the forklift  100  is entering into the zone  353  (or the central computer system  301  and/or the server  320  may automatically alert/notify the operator to re-position and/or tilt the load on the tines  200  to a safe vertical position and/or safe tilt angle). The equipment will also slow or stop if it detects the load is too high to pass under an obstruction and/or if it senses the lateral forces on the load are too great for the speed and turn angle of the equipment, and/or if it senses a sudden slippery or hazardous area marked with a sensor embedded sign by maintenance or emergency response teams. 
     The sensors  250 ,  350  and central computer system  301  may communicate with a locating system such as a Real Time Locating Service (RTLS). The locating system may be implemented on a suitable electronic processing device such as a computer associated with the server  320  or the central computer system  301 . The computer of the server  320  and central computer system  301  are configured to read and execute instructions stored on the non-transitory storage medium  307 ,  327  for implementing the RTLS to determine the current location of the forklift  100 . The server  320  may comprise a single server computer, a plurality of server computers, an ad hoc collection of network-based computers defining a cloud computing resource, etc., and/or combinations of the same. By way of non-limiting illustration, some examples of RTLS technologies include radio frequency identification based, or RFID-based, RTLS employing RFID tags disposed on or in tracked equipment; GPS-based tracking using GPS receivers (sensors) mounted to the forklift  100 ; WiFi based positioning (WPS) leveraging signal strength of WiFi access point (AP) connections with WiFi-enabled mobile devices; various combinations thereof; or so forth. In some embodiments, using Internet and/or other computer system(s), the current location of the portable device can be established by associating a geographic location with an Internet Protocol (IP) address, media access control (MAC) address, RFID, hardware embedded article/production number, embedded software numbers, Wi-Fi connection location, or device GPS coordinates. The location can be facilitated by automatically looking up an IP address on a WHOIS service and retrieving the registrant&#39;s physical address. In some examples, other mobile and/or semi-permanent sensors may be utilized which are allocated to Health and Safety, Emergency Response Teams, Hazmat Teams and Plant Maintenance Teams to provide real time risk avoidance strategy for the equipment and operators. 
     As mentioned, in some embodiments, the central computer system  301  (and/or the server  320 ) is interconnected to the tilt controls of the control panel  305  to ensure that a load is properly positioned on the tines  110 ,  200  and safely stabilized by tilting the mast  104 . Data measured by the sensors  250 ,  350  ensure compliance with OSHA requirements and may be recorded and stored in the storage medium  307 ,  327 . In these embodiments, sensors  250 ,  350  may be located in the horizontal and vertical position of the forklift  100 . The sensors  250 ,  350  are configured to measure the position of a load of the tines  110 ,  200 . Specifically, the sensors  250 ,  350  and computer system  301  (and/or the server  320 ) are configured to determine when the load is positioned as rearward as possible on the tines  110 ,  200 , close to the carriage  105 , and whether the tines  110 ,  200  are sufficiently tilting the load (e.g., by the operator tilting the mast  104 ). Thus, the smart fork system  300  will be able to determine a forklift operator&#39;s compliance with various OSHA requirements, such as OSHA requirement 1910.170(o)(5) which provides that “[a] load engaging means shall be placed under the load as far as possible; the mast shall be carefully tilted backward to stabilize the load.” Various sensors may be utilized, such as proximity sensors, tilt sensors, optical sensors, and/or force sensors. 
     In some embodiments, the central computer system  301  (and/or the server  320 ) may monitor the speed at which the operator tilts the mast  104  when the tines  110 ,  200  are loaded to ensure that the operator is carefully tilting the load per OSHA requirements. For example, a safe tilt speed may be ascertained and programmed into the central computer system  301  (and/or the server  320 ), and the central computer system  301  (and/or the server  320 ) may inhibit tilting the mast  104  (when loaded or unloaded) at speeds exceeding the ascertained safe tilt speed and/or provide notification to the operator that they are exceeding safe tilt speed limits. 
     In some embodiments, the sensors  250 ,  350  are utilized to ensure that the load is fully stable (i.e., longitudinally, laterally, and dynamically stable pursuant to OSHA regulations Appendix A of Section 1910.178). Upon determination that the forklift  100  is approaching unstable levels, the central computer system  301  (and/or the sever  320 ) is configured to issue warnings and/or disable certain functions of the forklift  100 . Various sensors may be utilized, such as proximity sensors, tilt sensors, optical sensors, and/or force sensors. A determination of the stability of a forklift  100  carrying a load is calculated based on the forklift&#39;s wheelbase or track, as well as the weight and location of the load and the forklift&#39;s counter weight location. The wheelbase and track are constants, the values of which may be stored in the non-transitory storage medium  307 ,  327  of the computer system  301  and/or the server  320 . 
     In some embodiments, the forklift  100  is equipped with a weight sensor or scale in communication with the central computer system  301  (and/or the server  320 ) configured to measure the weight of the load carried by the forklift  100 . For example, sensors in a hydraulic system of the forklift  100  may measure resistance to whatever object/load the forklift  100  is lifting, thus determining the weight of the object/load. However, it is to be appreciated that other systems known in the art for measuring the loads while on or off the forklift may be substituted therein without departing from the scope of the present disclosure. In some examples, the weight sensor may also communicate to the processor where the load was left to ensure it does not exceed weight restrictions of vertical racks, mezzanine or trailer. 
     Whether a load is stable depends on the moment of inertia of the load at one end of a system being greater than, equal to, or smaller than the object&#39;s moment at the system&#39;s other end. This principle can be seen in the way a seesaw or teeter-totter works: that is, if the product of the load and distance from the fulcrum (moment) is equal to the moment at the forklift&#39;s other end, the forklift is balanced and it will not move. However, if there is a greater moment at one end of the forklift, the forklift will try to move downward at the end with the greater moment. 
     The longitudinal stability of a counterbalanced forklift  100  depends on the forklift&#39;s moment and the moment of the load. In other words, if the mathematic product of the distance from the front wheels to the load&#39;s center of mass times the weight of the load is less than the moment of the forklift, the system is balanced and will not tip forward. However, if the moment of the load is greater than the moment of the forklift  100 , the greater moment of the load will force the forklift  100  to tip forward. To ensure that longitudinal stability is met, the sensors  250 ,  350  may be configured to measure the distance of the load from the wheels of the forklift  100 . For example, one or more sensors (e.g., the sensor  350 ) may be positioned on the shank  202 , the carriage  105 , and/or the frame  102  such that the sensor(s) can accurately measure the approximate distance of a load from the wheelbase. This collected position data is transmitted to the central computer system  301  (and/or the server  320 ), which utilizes such position data in combination with the determined or known weight of the load, to calculate the moment of the load. The moment of the load is compared to the known moment of the forklift  100  in order to determine the forklift&#39;s  100  propensity for tipping forward. The computer system  301  (and/or the server  320 ) may be configured to generate a warning to the operator (and/or other locally or remotely located persons) and/or disable functions based on the determined moment of the load. 
     The sensors  250 ,  350  and computer system  301  may also be configured to determine whether the center of mass of a loaded forklift  100  is within the stability triangle  402 . With reference to  FIG.  4   , a counterbalanced forklift may have a three-point suspension system, that is, the forklift  100  may be supported at three points A, B, and C. This may be true even if the forklift  100  has four wheels  160 . The forklift steer axle  404  is attached to the forklift  100  by a pivot pin in the steer axle&#39;s  404  center about the point A. Connecting the points A, B, and C, with imaginary lines defines a triangle representative of the forklift&#39;s  100  three-point support called the stability triangle  402 . The forklift  100  has a load center, which is represented in  FIG.  4    by a center of mass point  410 . The position of the center of mass point  410  relative to the forklift  100  will change/move depending on whether the tines  200  are supporting a load and how that load is oriented. Thus, the center of mass point  410  may be representative of the forklift&#39;s  100  load center, regardless of whether the forklift  100  is loaded or unloaded, except that it may be located in a different position relative to the forklift  100  than as illustrated in  FIG.  4    depending on the magnitude and/or orientation of the particular load. 
     When the forklift&#39;s  100  load center (i.e., the center of mass point  410 ) is located within the stability triangle  402 , the forklift  100  is stable and will not tip over. However, when the vehicle/load combination center of mass falls outside the stability triangle  402 , for example beyond a point  412 , the forklift  100  becomes unstable and may tip over. Like determining the longitudinal stability described above, the sensors  250 ,  350  are configured to measure the distance and weight of the load. Combined with known quantities such as the forklift&#39;s  100  weight properties and dimensions (stored and accessible via the storage medium  307 ,  327 ), the computer system  301  (and/or the server  320 ) may determine whether the loaded center of mass point  410  is within the boundaries of the stability triangle  402 . 
     The sensors  250 ,  350  and computer system  301  (and/or the server  320 ) may also be configured to determine the lateral stability of the forklift  100 . With reference to  FIGS.  5 A and  5 B , the lateral stability of a forklift  100  may be determined by the position of a “line of action”  512 , wherein the line of action  512  is a vertical line that passes through the combined forklift  100  and load&#39;s center of mass. That is, the forklift  100  has a forklift center of mass  502  and the load  500  has a load center of mass  503 , and a combined center of mass  504  may be calculated that accounts for both the forklift center of mass  502  and the load center of mass  503 , and the combined center of mass  504  is located between forklift center of mass  502  and the load center of mass  503 . When the forklift  100  is not loaded, the location of the forklift center of mass  502  is the only factor to be considered in determining the stability of the forklift  100 . As long as the line of action  512  of the combined center of mass  504  is located within the stability triangle  402  described above, the forklift  100  as illustrated in  FIG.  5 A  is stable and will not tip over. However, if the “line of action”  512  falls outside the stability triangle  402  as illustrated in  FIG.  5 B , the forklift  100  is not stable and may tip over. Factors that lead to the lateral stability of the forklift  100  may include the placement of the load  500  on the forklift  100 , the height of the load  500  above the surface  510  on which the forklift  100  is operation, and the forklift&#39;s degree of lean  505 . 
     The sensors  250 ,  350  and computer system  301  may also be configured to determine the dynamic stability of the forklift  100 . Up to this point, the stability of a forklift  100  has been discussed without considering the dynamic forces that result when the forklift  100  and load are put into motion. The weight&#39;s transfer and the resultant shift in the center of mass due to the dynamic forces created when the machine is moving, braking, cornering, lifting, tilting, and lowering loads, etc., are important stability considerations. When determining whether a load can be safely handled, the operator should exercise extra caution when handling loads that cause the forklift  100  to approach its maximum design characteristics. For example, if an operator is to handle a maximum load, the load should be carried at the lowest position possible, the forklift  100  should be accelerated slowly and evenly, and the forks or tines  200  should be tilted forward cautiously. However, no precise rules may be formulated to cover all of these eventualities. The sensors  250 ,  350  may be configured to measure acceleration of the tines  200  and/or of the forklift  100 . In combination with the known weight and weight distribution of the forklift  100  and a measured weight of the load, the dynamic forces may be calculated and warnings issued to the operator if the dynamic forces are measured above a threshold value that may cause the forklift  100  to tip. In other embodiments, the computer system  301  (and/or the server  320 ) restricts or limits the movement (e.g., speed, direction) of the tines  200 , carriage  105 , mast  104 , and forklift  100  in order to prevent tipping due to calculated dynamic instabilities. 
     Accordingly, the smart fork system  300  may generate data regarding various operating conditions of the forklift  100  and its various components. This data is accessible in real-time and may be stored for future use. Thus, the smart fork system  300  generates data that may be utilized to monitor operator performance in the field and/or for training operators in a simulated environment. The data thus collected and recorded may be used for various purposes, such as, for example (a) statistical analysis to compare impacts versus location versus operator to enhance driver training, to flag non-conformance, to improve operational safety, efficiency, environment, and process design, (b) to be used in any safety or quality investigation, and/or (c) be available to outside agencies or insurance providers to show enhanced compliance and lower insurance rates, etc. 
     Operator Interface System for Powered Industrial Vehicles 
     In accordance with another aspect of the present disclosure, an operator interface system for powered industrial vehicles is provided.  FIG.  6    illustrates an example of an operator interface system  600  for controlling powered industrial vehicles based on the field of view of an operator  602  of the vehicle, according to one or more embodiments of the present disclosure. It will be appreciated that the various components depicted in  FIG.  6    are for purposes of illustrating aspects of the example embodiment, and that other similar components, implemented via hardware, software, or a combination thereof, are capable of being substituted therein. The operator interface system  600  (hereinafter, the system  600 ) is configured to control the power or drivetrain of a powered industrial vehicle, e.g., the forklift  100  or other material handling equipment, based on data received from view point sensors such that the vehicle may only travel in the direction that the operator  602  is looking. Thus, the system  600  may interface with the drive train or power of the forklift  100  to permit travel in directions that are within the operator&#39;s  602  field of view. In some embodiments, the system  600  may inhibit travel of the forklift  100  in directions that do not align with or fall within the operator&#39;s  602  field of view, and/or the system  600  may provide an alert or notification to the operator  602  (and/or to other locally or remotely located persons) when the operator&#39;s  602  field of view does not correspond to the direction of travel of the forklift  100 . 
     The system  600  may include a sensing device  604  worn by the operator  602 , which may be in the form of a headband  605  or hat, and which aligns with or senses a field of vision or view of the operator  602 . The position of the operator&#39;s  602  head and/or eyes  603  are indicative of the operator&#39;s  602  field of view, and may be determined by forklift mounted sensors  610  that are in communication with a central computer system  620 . 
     In some embodiments, the sensing device  604  may include at least one sensor  606  that is recognizable by at least one sensor  610  mounted to the forklift frame  102  to thereby define a sensing perimeter around the operator  602  within the cab  108 . The sensing device  604  may include one or more additional sensors for sensing other parameters or conditions, for example, ambient environment parameters or conditions and/or parameters or conditions associated with the operator  602 . For example, the sensing device  604  may include sensors for monitoring weather conditions (temperature, moisture or rain, lightning, etc.) in which the forklift  100  is being operated. In some examples, the sensing device  604  may include sensors for monitoring the awareness, health, or condition of the operator  602  such as a temperature sensor, heart rate monitor, a timer tracking how long the operator  602  has been operating the forklift  100 , etc. 
       FIG.  6    illustrates two of the sensors  610  being mounted to a pair of pillars  612  of the frame  102 , however, one or more additional sensors  610  may be mounted elsewhere about the frame  102 . Thus, while only two pillars  612  and mounted sensors  610  are illustrated in the front-facing view of  FIG.  6   , the pillars  612  at the rear of the forklift  100  may also include sensors  610 . That is, a forklift  100  may have three or more pillars  612  surrounding the cab  108 , which may have sensors  610  for recognizing a position of the headband sensors  606 . Also, the sensors  610  may be mounted at different portions of the frame  102  (i.e., not the pillars  612 ). Thus, the system  600  may include more or less than two sensors  610 , which may be mounted to the pillars  612  of the frame  102  and/or at various other portions of the frame  102 . 
     In other embodiments, the sensing device  604  includes a unique pattern or marker  607 , which is recognized by the sensors  610 . For example, sensors  610  may be image sensors configured to view the unique markers  607  on the headband  605 . Based on the positioning of the unique marker  607  within the field of view of the image sensors  610 , the central computer system  620  may calculate the rotation position of the operator&#39;s  602  head. 
     In yet still other embodiments, a sensing device  604  does not need to be worn by an operator  602 . Rather, the sensors  610  may be configured to detect and track the movement of the operator&#39;s eyes  603 . Based on the positioning of the eyes  603  within the field of view of the image sensors  610 , the central computer system  620  may calculate the rotation position of the operator&#39;s  602  head. 
     As shown in  FIG.  6    and as described above, the system  600  includes a central control system that interfaces with a drive train  618  and/or power systems of the forklift  100 , and which is represented generally as the central computer system  620  that is capable of implementing the example method described below. The central computer system  620  may be variously embodied without departing from the scope of the present disclosure as an industrial computer, personal computer, tablet, smartphone or other known device that hosts a software platform and/or application. The example central computer system  620  includes a processor  624 , which performs the example method by execution of processing instructions  626  that are stored in memory  628  connected to the processor  624 , as well as controlling the overall operation of the central computer system  620 . 
     The central computer system  620  may also include a user interface similar to the user interface  304  of central computer system  301  for monitoring and controlling the various components of forklift  100 . The central computer system  620  is in electronic communication with the sensors  610  and is configured to receive (wired or wirelessly) data measured by the sensors  610  that relate to the position of the operator&#39;s  602  head while wearing the sensing device  604  or is configured to track the operator&#39;s eyes  603 . 
     The instructions  626  include a viewpoint module  630  configured to receive data from one of or both the forklift mounted sensors  610  or sensors  606  worn by the operator. The viewpoint module  630  utilizes the sensor data to determine the orientation of the operator&#39;s  602  head (and/or eyes  603 ) and associates the operator with field of view direction  608 . 
     The instructions  626  also include a drive module  632  that, when implemented by the processor  624 , controls the power systems and/or or drivetrain  618  of the forklift  100 . That is, the drive module  632  is configured to determine a direction of travel  609  of the forklift  100 . For example, if the control (e.g., steering wheel, joystick, steering bars, etc.) is manipulated such that the forklift  100  is configured to make a left turn, the drive module  632  in communication with the drivetrain  618  determines the direction of travel  609  corresponding with such a left turn. The drive module  632  is also configured to control at least one of the components of the forklift  100  that deliver power to the driving wheels. The drive module  632  receives the field of view direction  608  from the viewpoint module  360  and compares the view direction  608  to the determined direction of travel  609 . If the view direction  608  and direction of travel  609  are in substantial alignment, the drive module  632  allows the forklift  100  to travel in the shared direction. However, if the view direction  608  does not align (correspond) with the determined direction of travel  609 , e.g., the operator is looking away from the direction of travel  609 , then the drive module  632  controls the drivetrain  618  such that the forklift  100  is restricted from traveling in the direction of travel  609 . Accordingly, the system  600  interfaces with the forklift  100  to control or override the power or the drivetrain  618  of the forklift  100  such that the vehicle may only be driven in a direction that aligns with the actual vision or view of the operator  602  in real time. For example, optical or proximity sensors arrayed around the fork operator cage and on the operator may be used to ensure the operator is looking in the direction of travel. 
     The various components of the computer system  620  may all be connected by a data/control bus  625 . The processor  624  of the computer system  620  is in communication with an associated data storage  640  via a link  642  and is in communication with the sensor systems (e.g., with comprising sensors  606 ,  610 ,  250 ,  350 ) and drivetrain  618  via link  643 . A suitable communications link  642 ,  643  may include, for example, the public switched telephone network, a proprietary communications network, infrared, optical, or other suitable wired or wireless data communications. 
     In some embodiments, the system  600  may include sensors, such as sensors  250 ,  350 ,  606 ,  610  or recognition capabilities that detect when there is an obstruction  660  in the operator&#39;s view or in the path of the forklift  100  and provide alert/notification of the same. That is, an object module  634  is configured to receive sensor data regarding the environment of the forklift  100  and determine the presence of an obstruction  660  in a particular direction. If the obstruction  660  is in the direction of travel  609  the object module  634  and drive module  632  cooperate to provide an alert or restrict movement of the forklift  100  in that direction to avoid the obstruction  660 . The system  600  may require the operator  602  to manually override such an alert to continue traveling in the direction of the obstruction  660  or to continue traveling with an obstructed view. The system  600  may also provide notification of the same to other locally or remotely located persons. 
     The computer system  620  may also include an associated data storage  640  that corresponds to any organized collection of data used for one or more purposes. Implementation of the associated data storage  640  is capable of occurring on any mass storage device(s), for example, magnetic storage drives, a hard disk drive, optical storage devices, flash memory devices, or a suitable combination thereof. The associated data storage  640  may be implemented as a component of the computer system  620 , e.g., resident in memory  628 , or the like. The system  600  may then save data obtained during operation in a database  644  which may be utilized by training or safety personnel to ensure safe/correct operation of the vehicle  100 . 
     The system  600  may also include some safety features alerting training or safety personnel that a vehicle operator may need additional training if the power to the vehicle was disabled a predetermined number of times due to the operator not looking in the direction of the vehicle&#39;s travel and/or if the operator drove with obstructed vision or through an obstructed path too many times. In addition, the system may completely inhibit operation of the vehicle if the operator is not wearing the sensing device  604  unless overridden by safety/training personnel. The data thus collected and recorded may be used for a variety of purposes, for example, (a) statistical analysis to compare impacts versus location versus operator to enhance driver training, to flag non-conformance, to improve operational safety efficiency, environment and process design, (b) to grade operators for bonus or other remuneration based on performance, (c) to be used in any safety or quality investigation, (d) to be available to outside agencies or insurance providers to show enhanced compliance and to lower insurance rates, and/or (e) to show customers, owners or stockholders data regarding the safe handling of their product which may command higher fees or provide a competitive advantage, etc. 
     Integrated Control System for Powered Industrial Vehicles 
     In accordance with another aspect of the present disclosure and with reference to  FIG.  7   , an integrated control system  700  for powered industrial vehicles is provided. Generally, the integrated control system  700  (hereinafter, the system  700 ) controls the industrial vehicle (e.g., the forklift  100 ) such that the operator cannot perform a certain operation without first performing a different, prior operation first and/or such that the operator cannot perform two or more operations simultaneously which would result in unsafe operation. 
     The system  700  includes a central computer system  720 , which is capable of implementing the example method described below. The central computer system  720  is similar in some aspects to computer system  620  and may be best understood with reference thereto, having similar components, e.g., a processor  724  configured for processing instructions  726  that are stored in memory  728 . 
     The instructions  726  include a status module  730  that, when implemented by the processor  724 , determines a status of all of the operational systems  750  of the vehicle  100 . 
     Operational systems  750  include, but are not limited to, a braking system  751  (for stopping and slowing down the vehicle), a drive system  752  (for steering and moving the vehicle), a lifting system  753  (for manipulating the tines, carriage, and mast) a lighting system  754  (for controlling lights on the vehicle) and other system  755  for controlling other features that may be integrated into the vehicle. As a non-limiting example, the status module  730  is configured to determine whether the brakes of the braking system  751  are engaged (e.g., via the operator pressing a brake pedal or the like). As another non-limiting example, the status module  730  may also (or instead) be able to determine whether the throttle of the drive system  752  is being applied and moving the vehicle forward, in reverse, or in a direction. As another non-limiting example, the status module  730  may also be able to determine whether the lifting system  753  is actively translating a load up or down the mast  104  and if the mast  104  is in a tilted position. 
     In some embodiments, the status module  730  is configured to receive data from sensors  250 ,  350 ,  610  mounted to various locations of the forklift  100  and/or from one or more sensors  606  worn by the operator  602 , as described in greater detail above. The sensor data aids the status module  730  in determining a status of an operational system  750 . For example and without limitation, the sensors may detect positions of the forklift  100 , the mast  104 , the carriage  105 , and/or the tines  200 , the presence of a load on the tines  200 , the speed of the forklift  100 , and/or the direction the operator  602  is looking. 
     The instructions  726  also include an order module  732  that, when implemented by the processor  724 , controls the operation of one of the operational systems  750  based on a determined status of one or more components of the same operational system or other operational system  750 . The order module  732  restricts a desired movement of the forklift  100  until a first operation is performed. The order of operational functions may be stored in a database  744  on the data storage device  740  that is accessible from the processor  724  via data link  742 . For example and without limitation, the order module  732  may restrict movement of the lifting system  753  until the status module  730  detects that the brake pedal of the braking system  751  is first engaged. In other words, the lifting system  753  and braking system  751  are integrated such that the operation of one depends on the other. In another non-limiting example, the lifting system  753  is dependent on the status of the drive system  752 , such that if the throttle of the drive system  752  is engaged, the order module  732  restricts movement of the lifting system  753  and vice versa. 
     The system  700  may thus create a controlled environment for the operator to operate the vehicle  100 , and the controlled environment by which the user may operate the vehicle may be based on OSHA standards/rules. The system  700  may also provide feedback to the operator based on their performance which is stored in the data storage  740 . That is, the system  700  may also save data obtained during operation in a database  744 , which may be utilized by training or safety personnel to ensure safe/correct operation of the vehicle. 
     VR Simulator for Powered Industrial Vehicles 
     Embodiments of the present disclosure are also directed towards a material handling equipment simulator utilizable for training purposes. While the above embodiments are described with reference to use with the forklift  100  (or other material handling equipment), they may also be embodied within a simulator. Such simulator may be utilized for training purposes, for example, in a classroom setting when accrediting and teaching potential operators as to safe operation of the forklift  100 . The simulator may be utilized by organizations and institutions for accrediting and certifying potential operators in accordance with applicable standards and/or regulations. Also, the simulator may be utilized by companies desiring to train their equipment operators in accordance with their own company specific rules or regulations regarding use of the material handling equipment that may be even more stringent than more general industry-wide standards. Thus, the simulator may be utilized for skill development, skill testing and proof of training, re-training, proficiency certification or re-certification. 
     The simulator may be run on various types of computer systems and/or gaming platforms, such as a virtual reality (VR) console. The simulator system replicates material handling equipment, devices, operator movement and virtual device or equipment movement in a virtual environment. The virtual world may closely simulate the required ideal or non-ideal environment, equipment and operations the operator will experience during actual use in the field. The simulator system can be programmed with virtual paths, routes and associated activity prior to a facility or line actually being built. 
     The simulator system may be utilized in the design and planning of a new facility and its equipment. In this manner, the simulator system may be utilized to perform efficiency, safety, and time studies prior to the facility or equipment being created ordered or installed. For example, safety or delivery flaws in the simulated environment may be found prior to ordering facility equipment and/or facility construction. Also, efficiencies of the new facility, equipment layouts, and/or incorporation of proposed facility equipment or devices may be checked prior to ordering and construction. 
     Operators may use the simulator system to train virtually in the new environment prior to actually operating equipment in the new environment to increase accuracy and efficiency. Non-operators may also use the simulator system to enhance their understanding of working safely around the material handling equipment. 
     Hazards and hazardous conditions may be introduced in the virtual environment to capture actual driving and material handling characteristics against an ideal or acceptable result. Hazards and hazardous conditions may include, without limitation, pedestrians, poor loads or stacking, liquid on the operating floor, poor lighting conditions, poor weather conditions, etc. The results may be replayed with the correct behavior fed back to the operator. The operator can also interact with other equipment or devices, such as but not limited to scanners, displays, pens, etc. 
     Scores and instructional training can be maintained as test results and proof of training to third parties, such as accreditation institutions and organizations. Safety and efficiency can be improved by providing feedback to the operator regarding their actual actions in the virtual environment. For example, eye motion in the correct path of travel (as 85% of collisions are caused by not looking in the direction of travel) may be recorded and fed back to the operator. The operator may also be tested on a specific facility&#39;s rules of the road (for example, maintaining a 3-foot clearance from pedestrians etc.) by comparing ideal operation to actual operation. Also, a safety incident or specific training may be recreated in virtual reality for training of all associates instead of just giving an oral description of the safety incident or specific training. 
     The simulator system may capture speed, hand, body and eye movement, operating time, impacts (i.e., G-forces), dimensions of facilities and equipment, rules of the road, reaction to hazards, using virtual equipment, devices and environments that can be programmed into the system and held for data collection purposes or testing. The simulator system collects this data, which can then be used to check the level of training, ability, knowledge, safety or efficiency of the operator or operation. The data can be stored as proof of the training certification trial or efficiency of the operator in the virtual environment. 
     Operators may use the simulator system to practice in a virtual environment. This saves the cost of actual equipment, devices, space for training, and possible damage by inexperienced operators. Multiple operators may be trained at one time, which saves the cost of a live instruction. Operators may be exposed to hazards and learn how to safely and correctly handle them in a virtual environment, which would be too dangerous to provide actual real-life experience to them in a real (non-simulated) environment. The simulator system may record operator errors and provide feedback to the operator so they can see for themselves. The feedback may be provided instantaneously and in real time during the simulation and/or the feedback may be reported at a later time, for example, after the training simulation. The operator may then learn, witness, believe and correct their errors, which is faster and more effective than just verbally explaining the required correction to the operator as the operator will be obtaining simulated experience to learn from. The simulator system may be run again to reinforce the correction as many times as required to provide a benchmark and improvement results. The data may be stored for interested third parties as proof of training and competency. Operators may be re-certified using the simulator system to thereby save on teaching time, save on equipment space, damage and devices for corrections. Also, as mentioned above, different equipment, devices, layouts and facilities may be simulated prior to their order or construction to check safety, quality delivery locations and efficiency and material handling management systems prior to constructing the real environments. Safety, delivery and management issues may also be found and corrected, or new solutions attempted and tried prior to real environments being constructed, thereby cutting or eliminating costs associated with corrections. Experts or consultants may give feedback on the virtual environment prior to certifying final construction to save on construction or ordering delays. Operators may practice procedures in a virtual environment so they are more effective and make fewer errors when they enter the real environment, thereby saving on the cost of corrections. 
     The amount of virtual environments, hazards, data collection, and scenarios programmed in the simulator system are not limited and may be used for virtually any new material handling project, thereby adding versatility to the simulator system. 
     One or more illustrative embodiments incorporating the invention embodiments disclosed herein are presented herein. Not all features of a physical implementation are described or shown in this application for the sake of clarity. It is understood that in the development of a physical embodiment incorporating the embodiments of the present invention, numerous implementation-specific decisions are to be made to achieve the developer&#39;s goals, such as compliance with system-related, business-related, government-related and other constraints, which vary by implementation and from time to time. While a developer&#39;s efforts might be time-consuming, such efforts would be, nevertheless, a routine undertaking for those of ordinary skill the art and having benefit of this disclosure. 
     The methods illustrated throughout the specification may be implemented in a computer program product that may be executed on a computer. The computer program product may comprise a non-transitory computer-readable recording medium on which a control program is recorded, such as a disk, hard drive, or the like. Common forms of non-transitory computer-readable media include, for example, floppy disks, flexible disks, hard disks, magnetic tape, or any other magnetic storage medium, CD-ROM, DVD, or any other optical medium, a RAM, a PROM, an EPROM, a FLASH-EPROM, or other memory chip or cartridge, or any other tangible medium from which a computer can read and use. 
     To aid the Patent Office and any readers of this application and any resulting patent in interpreting the claims appended hereto, applicants do not intend any of the appended claims or claim elements to invoke 35 U.S.C. 112(f) unless the words “means for” or “step for” are explicitly used in the particular claim.