Abstract:
The motor compartment of a fork lift truck is modified so that the operator&#39;s feet extend into the space normally required by the motor compartment. A motor support structure is installed between the traction motor and the gear box which is connected to the steerable, powered wheel. The motor support structure occupies a smaller space than the traction motor itself, thus increasing the space available to the operator&#39;s compartment, at least in a limited vertical location adjacent to the support. With the traction motor out of the way, sufficient space for elevated pedals is provided, thus providing the operator ample space to operate the truck while seated. A battery compartment and hydraulic system of the truck are positioned adjacent to one another and ahead of the operator&#39;s compartment/motor compartment. In this way, the battery compartment and hydraulic system are positioned such that they are clear of the operator&#39;s compartment.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Patent Applications No. 60/057,137 filed Aug. 28, 1997 and entitled EXPANDED OPERATOR&#39;S COMPARTMENT FOR LIFT TRUCK; and, No. 60/058,102 filed Sep. 5, 1997 and entitled EXPANDED OPERATOR&#39;S COMPARTMENT FOR LIFT TRUCK which are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates in general to materials handling vehicles and, more particularly, to an expanded operator&#39;s compartment for such vehicles which facilitates operation of the vehicles, particularly in a seated position. While the present invention is generally applicable to materials handling vehicles, it is described herein with reference to a fork lift truck, specifically a rider reach truck, for which it is particularly applicable and initially being used. 
     An important consideration in the design of fork lift trucks, such as a rider reach truck, is the width of the truck which is limited, to a great extent, by the width of existing aisles in warehouses. Generally speaking, fork lift trucks are preferably no wider than approximately 48 inches in order to provide ample room for turning the trucks, and in some cases, for two trucks to pass one another in an aisle. However, when the operator is provided with the option of sitting while operating the truck, the operator&#39;s compartment must be made wide enough to permit the operator to sit comfortably within the compartment. 
     For example, in the case of a rider reach truck in which the operator can stand, perch or sit, the operator&#39;s compartment must be made wide enough to permit the operator&#39;s feet to be placed on elevated auxiliary pedals when the operator is seated so that the operator&#39;s eyes can be maintained at substantially the same level as when the operator is standing or perching. Such a rider reach truck is disclosed in U.S. Provisional Patent Applications No. 60/057,375 filed Aug. 28, 1997 and entitled THREE POSITION SEAT ASSEMBLY FOR LIFT TRUCK; and, No. 60/058,101 filed Sep. 5, 1997 and entitled THREE POSITION SEAT ASSEMBLY FOR LIFT TRUCK which are incorporated herein by reference. 
     Since the total width of the truck is the sum of the motor compartment and the operator&#39;s compartment, it follows that the operator&#39;s compartment cannot be expanded without encroaching on the space occupied by the motor compartment, and particularly the space occupied by the traction motor of the truck. Accordingly, there is a need for an expanded operator&#39;s compartment for a fork lift truck, such as a rider reach truck, which comfortably accommodates a seated operator yet is compatible with the motor compartment of the truck. Preferably, a battery compartment and hydraulic system of the truck would be positioned such that they do not encroach on such an expanded operator&#39;s compartment. 
     SUMMARY OF THE INVENTION 
     This need is met by the invention of the present application wherein the motor compartment of a fork lift truck is modified so that the operator&#39;s feet extend into the space normally required by the motor compartment. This is accomplished by installing a motor support structure between the traction motor and the gear box which is connected to the steerable, powered wheel. The motor support structure occupies a smaller space than the traction motor itself, thus increasing the space available to the operator&#39;s compartment, at least in a limited vertical location adjacent to the support. With the traction motor out of the way, sufficient space for elevated pedals is provided, thus providing the operator ample space to operate the truck while seated. It is also preferred to position a battery compartment and hydraulic system of the truck adjacent to one another, ahead of the operator&#39;s compartment and the motor compartment. In this way, the battery compartment and hydraulic system are positioned such that they are clear of the operator&#39;s compartment. 
     It is, thus, an object of the present invention to provide a materials handling vehicle which has an expanded operator&#39;s compart such that the operator may sit comfortably in addition to perching or standing while operating the vehicle. 
     Other objects and advantages of the invention will be apparent from the following description, the accompanying drawings and the appended claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view showing a rider reach truck incorporating an expanded operator&#39;s compartment in accordance with the present invention; 
     FIG. 2 is a perspective view of the power unit of the rider reach truck of FIG. 1 showing the various components included in the expanded operator&#39;s compartment; 
     FIG. 3 is another perspective view of the expanded operator&#39;s compartment showing elevated foot pedals which extend into a motor compartment of the power unit of the rider reach truck of FIG. 1; 
     FIG. 4 is an elevational end view of the operator&#39;s compartment and motor compartment, taken partly in cross section, showing the operator in a standing position; 
     FIG. 5 is an elevational end view of the operator&#39;s compartment and motor compartment, partly in cross section, showing the operator in a perching position; 
     FIG. 6 is an elevational end view of the operator&#39;s compartment and motor compartment, partly in cross section, showing the operator in a sitting position; 
     FIG. 7 is a perspective view of the operator&#39;s compartment with the housing for a control console removed and showing the elevated foot pedals; 
     FIG. 8 is a perspective view of the motor compartment with the housing for the motor compartment and a steering motor removed; 
     FIG. 9 is a plan view, partly in cross section taken along a horizontal plane passing through the section line  9 — 9  of FIG. 8, showing the relationship between a traction motor, a traction motor support and the elevated foot pedals; and 
     FIG. 10 is a perspective view of a battery and hydraulic system of the rider reach truck of FIG.  1 . 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Reference will now be made to FIGS. 1-3 which show a rider reach truck  10  that includes a power unit  15  including an operator&#39;s compartment  70 , a battery compartment  20 , and a motor compartment  400 . A battery in the battery compartment  20  (FIG. 10) supplies power to a traction motor  410  (FIGS. 4-9) located in a motor compartment  400  and connected to a steerable wheel  25  located at the left rear corner of the power unit  15  and to hydraulic motors, for example the motor of a motor-pump assembly (FIG.  10 ), which supply power to several different systems within the truck  10 . A caster wheel  30  is mounted at the right rear corner of the power unit  15 . A pair of outriggers  35  support the front end of the truck  10 . 
     A mast assembly  40  mounted to the front of the truck  10  includes an overhead guard  45 . A pair of forks  50  are carried on a fork carriage mechanism  55  which is carried on extendable mast elements  60 . The fork carriage mechanism  55  may include a reach mechanism to allow the forks  50  to be extended forward of the mast assembly  40 , a side shift mechanism to permit the forks  50  to be moved from side to side relative to the mast assembly  40 , and a tilt mechanism to permit the forks  50  to be tilted relative to horizontal. 
     In the operator&#39;s compartment  70  are mounted a steering tiller  75  for controlling the direction of travel of the truck and a control handle  80  for controlling the speed of travel and the forward and reverse direction of the truck  10  as well as fork height, fork extension, and fork tilt and side-shift. 
     Also located within the operator&#39;s compartment  70  is a seat assembly  90  which is attached to the right side  92  of the power unit  15 , as shown. The seat assembly  90  includes a back rest  95 , a seat  100 , and a perch or shelf  105 . The seat assembly is vertically adjustable for operator comfort. An armrest  110  is also supported on the seat assembly  90  for movement therewith. The control handle  80  is mounted on an arm  115  extending from the armrest  110 . 
     On the floor of the operator&#39;s compartment  70  are two pedals  120  and  125 . The left-hand pedal  120  operates an electric switch to control braking of the truck while the right-hand pedal  125  operates a power switch indicating the presence of the operator&#39;s foot thereon. Also located within the operator&#39;s compartment are three additional pedals: a pedal  130 , corresponding to pedal  120 ; a pedal  135 , corresponding to pedal  125 ; and a pedal  140 , which is an additional brake pedal. The operator must have one foot on and depress the pedal  120  or  130  in order for the vehicle to move; otherwise, the vehicle&#39;s brakes will be fully applied. The operator must also depress either pedal  125  or  135  in order for the vehicle to move, if it is stopped; if moving, removal of the foot from pedals  125  or  135  will cause the vehicle to coast. The switches controlled by pedals  125  and  135  are known as “presence”, “cut back” or “power” switches and indicate the presence of an operator within the operator&#39;s compartment  70 . The pedal  140  is an axillary brake switch; anytime the operator depresses pedal  140 , the brakes of the truck  10  will be immediately applied. 
     An operator&#39;s console  150  provides the operator with information regarding the status of the battery voltage and may provide additional information regarding the fork height, the weight of the load on the forks, and other information to assist the operator of the truck  10 . 
     FIGS. 4,  5 , and  6  illustrate the various positions an operator  200  can assume during operation of the truck  10 . FIG. 4 illustrates the stand mode of operation, FIG. 5 illustrates the perch mode of operation and FIG. 6 illustrates the sit mode of operation. In the stand mode, FIG. 4, the operator  200  is shown standing, the seat  100  is lowered, the shelf  105  is raised. In this operating mode, the operator  200  is essentially presented with a contoured, cradling surface to support the back side of the operator&#39;s body providing a fifth point of stability for the operator in addition to the hand and feet controls. The operator&#39;s feet are generally placed on the floor pedals  120  and  125 , as shown. 
     In the perch mode of FIG. 5, the shelf  105  is lowered to the position shown. This allows the operator  200  to lean back with his/her buttocks resting on or against the shelf partially to support the weight of the body. In this mode of operation, the feet are normally moved slightly forward, therefore the operator&#39;s heels are usually placed on the floor mounted pedals  120  and  125 . 
     The seat assembly  90  is adjustable vertically in order to place the seat assembly  90  at the vertical height that will ensure an appropriate and consistent eye level relative to the truck and the floor for each operator of the truck whether the operator is standing, perching or sitting. The dashed horizontal lines  204  and  206  in FIGS. 4-6 show the limited extent of vertical movement of the operator&#39;s eyes, provided the seat assembly  90  is properly adjusted. 
     If desired, the operator  200  shown in FIGS. 4 and 5 may rest one foot on the floor mounted pedals  120 ,  125 , and the other foot on the elevated pedals  130 ,  135 , and thus continue to operate the vehicle while changing position from time to time for variety and comfort. Additional details regarding the seat assembly may be obtained from referenced U.S. Provisional Patent Applications No. 60/057,375 filed Aug. 28, 1997 and entitled THREE POSITION SEAT ASSEMBLY FOR LIFT TRUCK; and, No. 60/058,101 filed Sep. 5, 1997 and entitled THREE POSITION SEAT ASSEMBLY FOR LIFT TRUCK. 
     Referring now to FIGS. 4-9, the motor compartment  400  includes a steering motor  420 , a motor support or support structure  430  and the traction motor  410  on which is mounted a brake  415 . The steering motor  420  has been removed in FIG. 8 in order to better show the support structure  430 . In a conventional reach truck, the traction motor  410  is mounted directly on a gear box  440  which is rotated by the steering motor  420  to control the direction of travel of the truck. The traction motor  410  is relatively large in diameter in order to deliver the power necessary to move a loaded truck, therefore the space available for expansion of the operator&#39;s compartment is limited. 
     A primary consideration in the design of fork lift trucks, such as a rider reach truck, is the width of the truck which, to a great extent, is limited by the width of existing aisles in warehouses. Generally speaking, fork lift trucks, like those of the type shown in the drawings, are limited to a width W, see FIGS. 1 and 4, of approximately 48 inches. However, when the operator is provided with the option of sitting while operating the truck, the operator&#39;s compartment must be made wide enough to permit the operator to sit comfortably within the compartment. For example, in the case of a rider reach truck in which the operator can stand, perch or sit as previously described, the operator&#39;s compartment must be made wide enough to permit the operator&#39;s feet to be placed on elevated auxiliary pedals when the operator is seated so that the operator&#39;s eyes can be maintained at substantially the same level as when the operator is standing or perching. 
     Since the total width W of the truck is the sum of the motor compartment and the operator&#39;s compartment, it follows that the operator&#39;s compartment cannot be expanded without infringing on the space occupied by the motor compartment, and particularly the space occupied by the traction motor. As shown in the truck  10  of FIGS. 4-9 which includes the invention of the present application, the operator&#39;s feet extend into the space occupied by the motor compartment  70 . This is enabled in the present invention by installing a motor support structure  430 , which occupies a smaller space than the motor itself. 
     The motor support structure  430  is square in cross section and is sufficiently strong to support the motor and the torque imposed on it when the motor is either supplying power to the wheel  25 , or braking the truck  10 . Preferably as illustrated, a corner of the motor support structure  430  is directed toward the operator&#39;s compartment  70  to expand the space available for extension of the operator&#39;s compartment  70  into the motor compartment  400 . Of course, other geometric cross sections or cross sections having at least one extension which narrows to a terminal end can be used for the motor support. For such alternates, the terminal end of the extension is directed toward the operator&#39;s compartment. A shaft  435  connects the motor  410  to the gear box  440 . 
     The knee wall  450  of the operator&#39;s compartment is recessed into the motor compartment  70  at a recessed knee wall section  460 . The outline of the motor  410  is shown in FIG. 9, as is the cross-section of the motor support structure  430 . The recessed knee wall section  460  is shown extending into the motor compartment  70  to approximately the center line of the motor  410  at the center of the pedals  130 ,  135 . 
     FIG. 10 shows the location of the hydraulic system of the truck  10 . Included in the hydraulic system are a motor-pump assembly  500 , a hydraulic reservoir  505 , a manifold  510  and hydraulic lines  515 . The hydraulic system is placed on the right side of the truck adjacent to the battery compartment  20  and under the armrest  110 . This location provides several advantages, removing pump and motor heat and noise from the operator, improved service access, and the addition of a gusset for the battery compartment  20 . Also, as is apparent from the drawings, this positioning of the battery compartment and the hydraulic system, i.e., adjacent to one another across the width of the truck and ahead of the operator&#39;s compartment and the motor compartment, ensures that there is no encroachment into the operator&#39;s compartment which might otherwise interfere with its expansion. 
     Having thus described the invention of the present application in detail and by reference to preferred embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims.