Patent Description:
Forklifts and other types of industrial vehicles operate in a variety of different conditions and settings. These vehicles typically include one or more sensors associated with a drive or traction motor for generating signals indicative of a speed, acceleration, and direction of motion of the traction motor, which is used to determine the speed, acceleration, and direction of motion of a driven wheel and thus the vehicle.

<CIT> discloses a load wheel assembly that may be mounted on and removed from a straddle arm or an outrigger of a materials handling vehicle. The load wheel assembly includes first and second spaced side members, at least one rotatable roller extending between the first and second side members, and a retainer for holding the roller between the side members. An interface structure further provides a connection between the load wheel assembly and a mounting structure on the materials handling vehicle, allowing for mounting and removal of the load wheel assembly.

Various aspects and embodiments of the present disclosure address various technical problems associated with the need for a sensor device that accurately detects a rotational speed of a wheel in an outrigger arm assembly yet allows components that wear out quickly to be repaired or replaced without replacing the sensor device. The present disclosure provides a first technical solution that involves directly monitoring a wheel speed, such as a wheel that is not driven and, hence, unlikely to slip, such that inconsistent rotation or slippage of an axle relative to the wheel bearings or slippage of a driven wheel with respect to a floor surface does not affect the accuracy of a vehicle speed calculation based on the measured non-driven wheel speed. Because the wheel speed is directly monitored, and because the wheel is non-driven, the wheel is unlikely to slip and, hence, the sensor device provides wheel speed information that allows vehicle speed to be accurately determined. Another technical solution provided herein is the use of one or more Hall-effect sensors, which, in combination with a magnetic target (e.g., a code ring), are much more sensitive and are typically effective over a much wider air gap range, as compared to, for example, an inductive proximity sensor or a back biased Hall sensor. Hence, the presently disclosed sensor device is less likely to be affected by variability in the air gap and need not conform to the tight tolerances and precise machining typically required by conventional sensor devices. A further technical solution involves placement of the sensor device such that frequently-replaced components of the outrigger arm assembly, e.g., the wheel bearings, wheels/wheel covers, and/or axles, may be repaired or replaced without disturbing or replacing the sensor device. The attachment and location of the sensor device also allows the sensor device to be easily accessed without the need to disassemble and reassemble the outrigger arm assembly, and many of the operations related to accessing the sensor may be performed by hand. The sensor device is relatively small, and lightweight, as compared to conventional sensors associated with complex bearing assemblies, and may be easily retrofitted onto existing vehicles. Other technical problems and corresponding solutions are set out herein.

In accordance with an aspect of the present disclosure, a wheel assembly including a sensor for measuring wheel movement is provided. The wheel assembly comprises a frame member; an axle fixed to the frame member; a wheel rotatably mounted to the axle, wherein the wheel comprises a wheel recess; a code ring located within the wheel recess for rotation with the wheel; and a sensor device coupled to the frame member and located adjacent to the code ring, in which the sensor device senses movement of the code ring and generates an output signal indicative of the wheel movement.

The frame member comprises opposing axle plates for supporting the axle. Each of the opposing axle plates comprises a bore for receiving the axle. One of the opposing axle plates comprises a further bore through which a portion of the sensor device at least partially extends. The wheel assembly further comprises a side member that is coupled to the one axle plate and comprises a cavity or an opening that receives and at least partially encloses the sensor device. The code ring may comprise a ring magnetized with alternating north and south poles around a perimeter of the ring. In some examples, the sensor device may comprise at least one Hall-effect sensor for sensing the alternating north and south poles as the code ring rotates and, based on sensing the alternating north and south poles, generating a corresponding output signal. In some particular examples, the sensor device may comprise first and second Hall-effect sensors that generate first and second output signals that are <NUM> degrees out of phase with one another.

In some configurations, the portion of the sensor device may extend completely through a thickness of the one axle plate and be aligned with the code ring. In other particular examples, the sensor device may comprise a housing with a housing bore extending through the housing and a fastener that extends through the housing bore and engages a tapped bore in the one axle plate.

In some examples, the wheel assembly may further comprise a cover plate coupled to an outer surface of the side member. In other examples, the wheel assembly may further comprise a cable guide member extending between the frame member and a support structure.

In other particular configurations, the wheel assembly may further comprise a first side member coupled to the one axle plate; a second side member coupled to a support structure and located adjacent to the first side member; a first cover plate coupled to an outer surface of the first side member; and a second cover plate coupled to an outer surface of the second side member, in which the first side member receives the sensor device and a cable extending from the sensor device and the second side member receives the cable extending from the first side member. In some examples, the second side member may comprise one or more apertures extending through a thickness of the second side member and one or more fasteners that extend through the apertures and engage one or more corresponding bores formed in one of an outer surface or a sidewall of the support structure. In some particular examples, the one or more apertures may serve as a drill guide for forming the one or more corresponding bores in the support structure.

The sensor device may comprise a housing with a housing bore extending through the housing and a fastener that extends through the housing bore and engages an additional bore in the one axle plate. The side member may further comprise one or more auxiliary bores that serve as a drill guide for forming one or more of the further bores or the additional bore.

In accordance with an aspect of the present disclosure, a materials handling vehicle is provided that comprises a power unit; a mast assembly secured to the power unit; a pair of forks coupled to the mast assembly, the forks being movable in height between a lowered position and a plurality of raised positions; and a pair of outrigger arm assemblies secured to the mast assembly. Each outrigger arm assembly comprises a frame member secured to the mast assembly. At least one of the outrigger assemblies comprises a wheel assembly as described in a previous aspect.

While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed that the present invention will be better understood from the following description in conjunction with the accompanying Drawing Figures, in which like reference numerals identify like elements, and wherein:.

In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration, and not by way of limitation, specific preferred embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and that changes may be made without departing from the spirit and scope of the present invention.

With reference to <FIG>, exemplary industrial vehicles <NUM>, <NUM> are shown. <FIG> and <FIG> illustrate an exemplary materials handling vehicle in the form of a reach truck <NUM>, and <FIG> illustrates an exemplary materials handling vehicle in the form of an order picker vehicle <NUM> (also referred to as a stock picker vehicle). While the present disclosure is made with reference to the illustrated vehicles <NUM>, <NUM>, it will be apparent to those of skill in the art that the vehicles <NUM>, <NUM> may comprise a variety of other industrial vehicles, such as a turret truck, a tow tractor, a rider pallet truck, a walkie stacker truck, a counterbalance forklift truck, etc., and that the following description of the invention with reference to the Figures should not be limited to a reach truck or order picker vehicle unless otherwise specified.

With reference to <FIG>, the reach truck <NUM> may comprise a power unit <NUM> comprising a frame <NUM>, an operator compartment <NUM>, an overhead guard <NUM>, a mast assembly <NUM>, a fork carriage assembly <NUM> and a pair of forks <NUM> coupled to the fork carriage assembly <NUM> for movement with the fork carriage assembly <NUM>. The order picker vehicle <NUM> may comprise a power unit <NUM> comprising a frame <NUM>, an operator compartment <NUM>, an overhead guard <NUM>, a mast assembly <NUM>, a platform assembly <NUM>, and a pair of forks <NUM> coupled to the platform assembly <NUM> for movement with the platform assembly <NUM>. The mast assembly <NUM>, <NUM> is secured to the power unit <NUM>, <NUM> and is positioned between a pair of outrigger arm assemblies <NUM>, <NUM>. In some examples, a battery (not shown), which may be housed in a battery compartment 104A, 204A within the frame <NUM>, <NUM>, supplies power to a drive or traction motor (not shown) and to one or more hydraulic motors (not shown). The power unit <NUM>, <NUM> of each vehicle <NUM>, <NUM> is supported on a plurality of wheels that enable the vehicles <NUM>, <NUM> to move across a floor surface F (see <FIG>). With reference to <FIG> and <FIG>, the reach truck <NUM> may comprise rear wheel assemblies comprising a steerable, powered wheel <NUM> located at the left rear of the power unit <NUM> and a caster wheel <NUM> located at the right rear of the power unit <NUM>. Both the reach truck <NUM> and the order picker vehicle <NUM> may comprise the pair of outrigger arm assemblies <NUM>, <NUM> comprising one or more non-driven outrigger wheels <NUM>, <NUM>, <NUM>, <NUM>, wherein the outrigger arm assemblies <NUM>, <NUM> are fixed to the mast assembly <NUM>, <NUM> and extend from the front of the vehicle <NUM>, <NUM> (see <FIG>; only outrigger arm assembly <NUM> is shown in <FIG> and <FIG> and only outrigger arm assembly <NUM> is shown in <FIG>). The order picker vehicle <NUM> may further comprise one or more rear wheel assemblies (not visible in <FIG>) that are located under the rear of the power unit <NUM> and may comprise a steerable, powered wheel and an optional caster wheel.

With reference to <FIG> and <FIG>, the mast assembly <NUM>, <NUM> of the vehicles <NUM>, <NUM> may comprise a fixed mast member <NUM>, <NUM> affixed to the frame <NUM>, <NUM> and one or more nested, movable mast members (not separately labeled). It is noted that the vehicles <NUM>, <NUM> may comprise two moveable mast members or additional or fewer movable mast members than two. The forks <NUM>, <NUM> are movable in height between a lowered position and a plurality of raised positions. In the reach truck <NUM>, the fork carriage assembly <NUM> is coupled to and is vertically movable along the mast assembly <NUM>. As noted above, the forks <NUM> in the reach truck <NUM> are coupled to the fork carriage assembly <NUM> for movement with the fork carriage assembly <NUM>. In the order picker vehicle <NUM>, the platform assembly <NUM>, which includes the operator compartment <NUM>, is coupled to and is vertically movable along the mast assembly <NUM>. The forks <NUM> may extend outward from a forward edge of the platform assembly <NUM>, as shown in <FIG>. In some examples, the forks <NUM> may be welded to or hooked onto the platform assembly <NUM>. In other examples (not shown), the forks <NUM> of the order picker vehicle <NUM> may be supported on an auxiliary mast for vertical movement relative to the operator compartment <NUM>, wherein the auxiliary mast is mounted to the platform assembly <NUM>. In any event, in the order picker vehicle <NUM>, the forks <NUM> are coupled to the mast assembly <NUM> via the platform assembly <NUM> alone or via the platform assembly <NUM> and the auxiliary mast.

In both vehicles <NUM>, <NUM>, the hydraulic motor(s) supply power to several different systems, such as one or more hydraulic cylinders (not shown) for effecting generally vertical movement of the movable mast members relative to the fixed mast member <NUM>, <NUM> and generally vertical movement of the fork carriage assembly <NUM> of the reach truck <NUM> or the platform assembly <NUM> of the order picker vehicle <NUM> relative to a movable mast member of the mast assembly <NUM>, <NUM>. The outrigger arm assemblies <NUM>, <NUM> are secured to the mast assembly <NUM>, <NUM>, which, in turn, is secured to the frame <NUM>, <NUM>. The outrigger arm assemblies <NUM>, <NUM> are positioned such that the forks <NUM>, <NUM>, and any loads/pallets (not shown) carried thereby, may be lowered to the floor surface F between the outrigger arm assemblies <NUM>, <NUM>, without interference (see <FIG>). As shown in <FIG>, the outrigger arm assemblies <NUM>, <NUM> in some examples may extend laterally outwardly.

<FIG> is a detailed view of exemplary outrigger arm assemblies <NUM>, <NUM>, which may be located on either vehicle <NUM>, <NUM> depicted in <FIG>. Each outrigger arm assembly <NUM>, <NUM> comprises a respective frame member <NUM>, <NUM> comprising a forwardly extending arm or support structure <NUM>, <NUM> fixedly coupled, such as by welding, to the mast assembly <NUM> and a pair of opposing axle plates <NUM>, <NUM>, <NUM>, <NUM> fixedly coupled, such as by welding, to a forward end of the corresponding support structure <NUM>, <NUM>. Each outrigger arm assembly <NUM>, <NUM> may further comprise a divider <NUM>, <NUM> extending between respective pairs of the axle plates <NUM>, <NUM> and <NUM>, <NUM> to provide structural support for the axle plates <NUM>, <NUM>, <NUM>, <NUM>. One or more first axles <NUM>, <NUM> are fixed to the frame member <NUM> of the outrigger arm assembly <NUM>, and more specifically, to the pair of axle plates <NUM>, <NUM>, as described herein such that the axles <NUM>, <NUM> do not rotate or rotate only minimally relative to the axle plates <NUM>, <NUM>. One or more second axles <NUM>, <NUM> are fixed to the frame member <NUM>, and more specifically, to the pair of axle plates <NUM>, <NUM> of the outrigger arm assembly <NUM> such that the axles <NUM>, <NUM> do not rotate or rotate only minimally relative to the axle plates <NUM>, <NUM>. As used herein with respect to the axles <NUM>, <NUM>, <NUM>, <NUM>, the term "fixed" means that there is no movement or only a slight amount of movement of the axles <NUM>, <NUM>, <NUM>, <NUM> relative to the axle plates <NUM>, <NUM>, <NUM>, <NUM> and/or other components of the frame members <NUM>, <NUM>. A wheel <NUM>, <NUM>, <NUM>, <NUM> is rotatably mounted to and supported on a respective one of the fixed axles <NUM>, <NUM>, <NUM>, <NUM>. A side member <NUM> is coupled to an outer surface (not separately labeled; see reference numeral <NUM>-<NUM> in <FIG>, <FIG>, and <FIG>) of the axle plate <NUM> of one of the outrigger arm assemblies <NUM>.

With reference to <FIG>, <FIG>, and <FIG>, a torque arm <NUM>, <NUM> may be coupled between each frame member <NUM>, <NUM> and the mast assembly <NUM>. The torque arms <NUM>, <NUM> may comprise a quadrilateral shape, as shown in <FIG> and <FIG>, or a teardrop shape having a rounded end that tapers to a generally pointed end, as shown in <FIG> and <FIG>. A transverse plate <NUM> extends between and is fixed to the outrigger arm assemblies <NUM> and <NUM>. The fixed mast member <NUM> may comprise vertical mast rails 112A, 112B that are spaced apart and welded at their lower ends to the torque arms <NUM>, <NUM> and the transverse plate <NUM> and at their upper ends to a horizontally extending upper fixed mast rail 112C (the horizontally extending upper fixed mast rail 212C is shown in <FIG> with respect to the vehicle <NUM>). The torque arms <NUM>, <NUM>, the transverse plate <NUM>, and the support structures <NUM>, <NUM> may all be welded together to form a main frame that is bolted to the frame <NUM> of the power unit <NUM>. The main frame thus transfers weight from the wheels <NUM>, <NUM>, <NUM>, <NUM> at the forward portion of the outrigger arm assemblies <NUM>, <NUM> to the mast assembly <NUM> and the frame <NUM>.

<FIG> is an exploded view of the outrigger arm assembly <NUM> of <FIG> comprising the side member <NUM>, in which only one wheel <NUM> is shown to illustrate other aspects of the outrigger arm assembly <NUM> in detail (see also <FIG>, which depicts both wheels <NUM>, <NUM>). <FIG> is a detailed view of a code ring <NUM>. <FIG> is a cross-sectional view of a portion of the outrigger arm assembly <NUM> in <FIG> taken along line <NUM>-<NUM>, and <FIG> is a cross-sectional view taken along line <NUM>-<NUM> in <FIG>.

With reference to <FIG> and <FIG>, each axle plate <NUM>, <NUM> comprises bores 144A, 144B, 146A, 146B extending through a thickness of the axle plate <NUM>, <NUM> for receiving a respective end 140A, 142A or a portion 140E, 142E of the axles <NUM>, <NUM>. The axles <NUM>, <NUM> have first ends 140A, 142A having diameters that are equal to diameters of middle or intermediate portions of the axles <NUM>, <NUM>. The axles <NUM>, <NUM> have second ends comprising collars 140B, 142B having diameters that are greater than the diameters of the middle or intermediate portions of the axles <NUM>, <NUM>. The axle plate <NUM> that receives the first ends 140A, 142A of the axles <NUM>, <NUM> comprises a slot 144C that is formed along a longitudinal length of the axle plate <NUM> and that transects the axle plate bores 144A, 144B of the axle plate <NUM> (see also <FIG> and <FIG>; the axle plate <NUM> may comprise a corresponding slot 166C). The first ends 140A, 142A of each axle <NUM>, <NUM> comprise an aperture 140C, 142C extending through a thickness of the axle <NUM>, <NUM> for receiving a roll pin 140D, 142D. During installation, the first end 140A, 142A of each axle <NUM>, <NUM> is inserted through the side member <NUM> and then through the axle plate <NUM> via a respective one of the bores 146A, 146B and a corresponding wheel <NUM>, <NUM> and received in a respective one of the bores 144A, 144B of the axle plate <NUM>. The roll pin 140D, 142D is inserted into the aperture 140C, 142C in the first end 140A, 142A of a respective one of the axles <NUM>, <NUM> via the slot 144C and may be, for example, hammered into position such that the pin 140D, 142D is held in place via a friction fit. As shown in <FIG>, a length of the roll pins 140D, 142D is greater than the diameter of the first ends 140A, 142A of the axles <NUM>, <NUM> as well as the diameters of the axle plate bores 144A, 144B of the axle plate <NUM>. Hence, the roll pins 140D, 142D protrude from either side of each axle <NUM>, <NUM> and engage a portion of the axle plate <NUM> surrounding the axle plate bores 144A, 144B, thereby securing the first ends 140A, 142A of the axles <NUM>, <NUM> in the axle plate bores 144A, 144B and preventing axial movement of the axles <NUM>, <NUM> out of the bores 144A, 144B in a direction away from the axle plate <NUM>. The slot 144C has a height H (see <FIG>) that is sized so as to allow very little, if any rotation, of the pins 140D, 142D in the slot 144C, thereby preventing rotation or allowing only very little rotation of the axles <NUM>, <NUM> in the axle plates <NUM>, <NUM>.

The side member <NUM> may comprise one or more openings 180A, 180B through which the axle(s) <NUM>, <NUM> are received, as shown in <FIG> and <FIG>. The side member <NUM> may also comprise recesses 180C, 180D surrounding the openings 180A, 180B, wherein the recesses 180C, 180D have diameters that are larger than the diameters of the openings 180A, 180B and a depth having a dimension of about <NUM> inches to about <NUM> inches. In some particular examples, the recesses 180C, 180D may comprise a depth of about <NUM> inches. The axle collars 140B and 142B are received in the recesses 180C, 180D during assembly of the axles <NUM>, <NUM> in the axle plates <NUM>, <NUM>. The axle collars 140B, 142B circumferentially engage a circumferential portion of the side member <NUM> defining a base portion of each of the recesses 180C, 180D to maintain the axles <NUM>, <NUM> properly positioned relative to the side member <NUM>, i.e., so as to prevent the axles <NUM>, <NUM> from moving axially completely through the side member <NUM> in a direction toward the axle plates <NUM> and <NUM>. With reference to <FIG> and <FIG>, one or more washers <NUM> may be provided on the axles <NUM>, <NUM> between each wheel <NUM>, <NUM> and inner surfaces <NUM>-<NUM>, <NUM>-<NUM> of the axle plates <NUM>, <NUM> to space the wheels <NUM>, <NUM> from the axle plates <NUM>, <NUM>.

With reference to <FIG>, <FIG>, and <FIG>, each wheel <NUM>, <NUM> comprises a casted wheel 132A, 134A and an inner bearing 133A, 135A and an outer bearing 133B, 135B mounted within the respective casted wheel 132A, 134A, wherein each bearing 133A, 133B, 135A, 135B comprises an opening 233A, 233B, 235A, 235B that receives a corresponding one of the axles <NUM>, <NUM>. Each wheel <NUM>, <NUM> also comprises a wheel cover 132B, 134B formed over the corresponding casted wheel 132A, 134A made, for example, from polyurethane. At least one of the casted wheels, e.g., wheel 132A, comprises a wheel recess <NUM> in a sidewall (not separately labeled) of the casted wheel 132A that is concentric with the bearing openings 233A, 233B. The wheel recess <NUM> may be machined into the sidewall of the casted wheel 132A. A code ring <NUM> is located and fixed within the wheel recess <NUM> such that the code ring <NUM> rotates with the wheel <NUM>. As shown in <FIG>, the code ring <NUM> may comprise a magnetized ring with alternating north N and south S poles around a perimeter or circumference <NUM> of the magnetized ring. The code ring <NUM> may comprise a polymer-bonded magnet, such as bonded ferrite, with a magnetized side <NUM> that faces toward the inner surface <NUM>-<NUM> of the axle plate <NUM>. In some particular examples, the code ring <NUM> may comprise <NUM> alternating N/S poles (<NUM> N and <NUM>) around the perimeter <NUM>, as shown in <FIG>. Suitable code rings may be purchased, for example, from Phoenix America, Inc. (Fort Wayne, IN).

As shown in <FIG>, a sensor device <NUM> is coupled to the frame member <NUM> of the outrigger arm assembly <NUM>. In particular, the sensor device <NUM> may be coupled to the outer surface <NUM>-<NUM> of the inner axle plate <NUM> of the outrigger arm assembly <NUM>. The sensor device <NUM> may comprise a housing <NUM> having a main body 300A with a bore <NUM> extending through a thickness of the main body 300A of the housing <NUM>. A fastener <NUM> may extend through the bore <NUM> and engage a bore <NUM> that is formed in the axle plate <NUM> to couple the main body 300A of the housing <NUM> to the outer surface <NUM>-<NUM> of the axle plate <NUM>. The fastener <NUM> may comprise, for example, a screw, a bolt, or other suitable type of fastener. In some examples, the bore <NUM> may extend fully through the thickness of the axle plate <NUM> and be threaded. In other examples, the bore <NUM> may comprise a blind or tapped bore that extends partially through the thickness of the axle plate <NUM>. As described herein, the sensor device <NUM> comprises a cable <NUM> that extends from the sensor device <NUM> toward the mast assembly <NUM> and is coupled to one or more components, such as a power supply <NUM> and a signal processor <NUM>.

As shown in <FIG>, <FIG>, and <FIG>, the axle plate <NUM> may comprise a further bore <NUM> extending through the thickness of the axle plate <NUM>. A portion 300B of the housing <NUM> of the sensor device <NUM> (also referred to herein as a portion 300B of the sensor device <NUM>) may extend out of plane with the main body 300A of the housing <NUM> of the sensor device <NUM>. The portion 300B, which may include sensing elements as described herein, extends at least partially through the bore <NUM>. The portion 300B of the housing <NUM> of the sensor device <NUM> may extend through the axle plate <NUM> such that an outermost surface (not separately labeled) of the portion 300B is either flush with the inner surface <NUM>-<NUM> of the axle plate <NUM> or slightly recessed within the axle plate <NUM>, as best seen in <FIG> and <FIG>.

The side member <NUM> may be positioned over the sensor device <NUM> to protect the sensor device <NUM> and the cable <NUM> from impacts and from contamination by foreign matter such as dirt, water, etc. As shown in <FIG> and <FIG>, a cavity <NUM> may be defined in an inner surface <NUM>-<NUM> of the side member <NUM> that faces the axle plate <NUM>. The cavity <NUM> receives and encloses the sensor device <NUM>. The inner surface <NUM>-<NUM> of the side member <NUM> may also comprise a channel (not shown) that receives the cable <NUM> extending from the sensor device <NUM> and secures the cable <NUM> adjacent to the outer surface <NUM>-<NUM> of the axle plate <NUM>. As shown in <FIG>, the side member <NUM> may comprise auxiliary bores <NUM> corresponding to the bores <NUM>, <NUM> formed in the axle plate <NUM>. The auxiliary bores <NUM> may serve as drill guides for creating the bores <NUM>, <NUM> in the axle plate <NUM>, particularly for purposes of retrofitting existing vehicles with sensor devices <NUM>. Because the side member <NUM> is mounted via the axles <NUM>, <NUM>, the auxiliary bores <NUM> formed in the side member <NUM> will be aligned with the desired location on the axle plate <NUM> following installation of the side member <NUM> on the axle plate <NUM>. The side member <NUM> is held in position against the axle plate <NUM> via the axles <NUM> and <NUM> and the axle collars 140B, 142B positioned in the recesses 180C, 180D of the side member <NUM>.

<FIG> and <FIG> are detailed views of additional exemplary outrigger arm assemblies <NUM>, <NUM>, which may be located on either vehicle <NUM>, <NUM> depicted in <FIG>. <FIG> is an exploded view of the outrigger arm assembly <NUM> of <FIG>, and <FIG> is a detailed exploded view of a portion of the outrigger arm assembly <NUM> of <FIG>. <FIG> is a cross-sectional view of a portion of the outrigger arm assembly <NUM> in <FIG> taken along view line <NUM>-<NUM>, and <FIG> is a cross-sectional view taken along line <NUM>-<NUM> in <FIG>.

The outrigger arm assemblies <NUM>, <NUM> depicted in <FIG> may be substantially similar in structure to the outrigger arm assemblies <NUM>, <NUM> depicted in <FIG>, <FIG>, <FIG>, and <FIG>. Some components are removed and labeling of some components is eliminated in <FIG> to illustrate other aspects of the invention in detail. With reference to <FIG> and <FIG>, each outrigger arm assembly <NUM>, <NUM> comprises a respective frame member <NUM>, <NUM> comprising a support structure <NUM>, <NUM> fixedly coupled to the mast assembly <NUM>, a pair of opposing axle plates <NUM>, <NUM>, <NUM>, <NUM> fixedly coupled to a forward end of the corresponding support structure <NUM>, <NUM>, and a divider <NUM>, <NUM> extending between respective pairs of the axle plates <NUM>, <NUM> and <NUM>, <NUM>. One or more first axles <NUM>, <NUM> are fixed to the frame member <NUM> of the outrigger arm assembly <NUM>, and more specifically, to the pair of axle plates <NUM>, <NUM>. One or more second axles <NUM>, <NUM> are fixed to the frame member <NUM>, and more specifically, to the pair of axle plates <NUM>, <NUM> of the outrigger arm assembly <NUM>. A wheel <NUM>, <NUM>, <NUM>, <NUM> is rotatably mounted to and supported on a respective one of the fixed axles <NUM>, <NUM>, <NUM>, <NUM>. A torque arm <NUM>, <NUM> may be coupled between each frame member <NUM>, <NUM> and the mast assembly <NUM>. As noted above, the fixed mast member <NUM> may comprise first and second fixed vertical mast rails (only one vertical mast rail 112A is shown in phantom in <FIG> and <FIG>; see <FIG>). A transverse plate <NUM> extends between and is fixed to the outrigger arm assemblies <NUM> and <NUM>. As described above, the torque arms <NUM>, <NUM>, the transverse plate <NUM>, and the support structures <NUM>, <NUM> may be welded together to form a main frame that is bolted to the frame of the power unit (not shown; see <FIG>), and the vertical mast rails 112A are welded to the torque arms <NUM>, <NUM> and the transverse plate <NUM>.

As shown in <FIG>, <FIG>, and <FIG>, one of the outrigger arm assemblies <NUM> comprises a first side member <NUM> coupled to an outer surface <NUM>-<NUM> of the axle plate <NUM>, a first cover plate <NUM> coupled to the first side member <NUM>, a second side member <NUM> coupled to an upper surface <NUM>-<NUM> of the support structure <NUM> adjacent to the first side member <NUM>, and a second cover plate <NUM> coupled to the second side member <NUM>. The cover plates <NUM>, <NUM> are removed in <FIG> to illustrate additional details of the side members <NUM>, <NUM>. A cable guide member <NUM> extends between the support structure <NUM> and a support member <NUM> that is coupled to the transverse plate <NUM>. As described in more detail with respect to <FIG>, <FIG>, and <FIG>, the first side member <NUM> receives a sensor device <NUM>, and the first and second side members <NUM>, <NUM> and the cable guide member <NUM> receive a cable <NUM> extending from the sensor device <NUM> toward the mast assembly <NUM>. The side members <NUM>, <NUM> protect the cable <NUM> and may isolate the cable <NUM> from contact with the axle plate <NUM> and the support structure <NUM>. Although not shown, the configuration depicted in <FIG> may include one or more similar structures that receive and protect the cable <NUM> extending from the sensor device <NUM> toward the mast assembly <NUM>.

With reference to <FIG> and <FIG>, each axle plate <NUM>, <NUM> of the outrigger arm assembly <NUM> comprises respective bores 144A, 144B, 146A, 146B extending through a thickness of the axle plate <NUM>, <NUM> for receiving a respective first end 140A, 142A or portion 140E, 142E of each axle <NUM>, <NUM>. The axle plate <NUM> that receives the first ends 140A, 142A of the axles <NUM>, <NUM> comprises a slot 144C formed along the longitudinal length of the axle plate <NUM> (see also <FIG>, <FIG>, and <FIG>; the axle plate <NUM> may comprise a corresponding slot 166C). The first ends 140A, 142A of each axle <NUM>, <NUM> comprise an aperture 140C, 142C extending through a thickness of the axle <NUM>, <NUM> for receiving a roll pin 140D, as shown in <FIG> and <FIG> (only one roll pin is shown in <FIG>; see <FIG> depicting roll pins 140D, 142D). The axles <NUM>, <NUM> may be installed in the axle plates <NUM>, <NUM> using the roll pins as described herein such that the axles <NUM>, <NUM> do not rotate or rotate only minimally relative to the axle plates <NUM>, <NUM>.

With continued reference to <FIG> and <FIG>, the first side member <NUM> may comprise openings 400A, 400B and recesses 400C, 400D surrounding the openings 400A, 400B. As previously described, the openings 400A, 400B receive the axles <NUM>, <NUM>, and the recesses 400C, 400D receive the axle collars 140B, 142B, which circumferentially engage a base portion of each of the recesses 400C, 400D to properly position the axles <NUM>, <NUM>. One or more washers (not labeled; see reference numeral <NUM> in <FIG> and <FIG>) may be provided on the axles <NUM>, <NUM>. As previously described, each wheel <NUM>, <NUM> may comprise a casted wheel and inner and outer bearings with openings (not separately labeled) that receive a corresponding one of the axles <NUM>, <NUM>. At least one of the casted wheels, e.g., the casted wheel of wheel <NUM>, comprises a wheel recess <NUM> that is formed in a sidewall of the casted wheel and is concentric with the bearing openings. A code ring <NUM>, which may be substantially similar to the code ring <NUM> depicted in <FIG>, is located and fixed within the wheel recess <NUM> such that the code ring <NUM> rotates with the wheel <NUM>.

As shown in <FIG>, <FIG>, <FIG>, and <FIG>, the sensor device <NUM> and its cable <NUM> may be positioned adjacent to the outrigger arm assembly <NUM> and protected via the first and second side members <NUM>, <NUM>. The sensor device <NUM> may be substantially similar to the sensor device <NUM> depicted in <FIG>, <FIG>, <FIG>, and <FIG>. The sensor device <NUM> may comprise a housing <NUM> having a main body 300A and a portion 300B that extends out of plane with the main body 300A. A cable <NUM> extends from the sensor device <NUM> toward the mast assembly <NUM>. The first side member <NUM> comprises an opening <NUM> that extends through a thickness of the first side member <NUM> and is designed to receive and partially enclose the sensor device <NUM>. A fastener <NUM> may extend through a bore formed in the main body 300A of the housing <NUM> of the sensor device <NUM> and engage a bore <NUM> that is formed in the axle plate <NUM> such that the main body 300A of the housing <NUM> of the sensor device <NUM> is directly coupled to the outer surface <NUM>-<NUM> of the axle plate <NUM>, as shown in <FIG> and <FIG>. The axle plate <NUM> may comprise a further bore <NUM> extending through the thickness of the axle plate <NUM>, and the portion 300B of the housing <NUM> of the sensor device <NUM>, which may include sensing elements as described herein, extends at least partially through the bore <NUM> such that an outermost surface (not separately labeled) of the portion 300B is either flush with the inner surface <NUM>-<NUM> of the axle plate <NUM> or slightly recessed within the axle plate <NUM>, as best seen in <FIG> and <FIG>. The thickness of the first side member <NUM> may be greater than or equal to a thickness of the main body 300A of the housing of the sensor device <NUM>, as depicted in <FIG> and <FIG>.

A channel comprising a first cable guide <NUM> is defined so as to extend inwardly from an outer surface <NUM>-<NUM> of the first side member <NUM> and may extend partially or completely through a thickness of the first side member <NUM>, as shown in <FIG> and <FIG>. The first cable guide <NUM> receives the cable <NUM> extending from the sensor device <NUM>. In some examples, at least a section of the first cable guide <NUM> extends only partially through the thickness of the first side member <NUM> such that the cable <NUM> is isolated from and not in contact with the outer surface <NUM>-<NUM> of the axle plate <NUM>. The sensor device <NUM> may be positioned such that the cable <NUM> extends from the sensor device <NUM> at an angle toward the upper or lower surface (not separately labeled) of the axle plate <NUM>. A section of the first cable guide <NUM> may be curved to gradually change a direction of the cable <NUM> such that the cable <NUM> extends along the longitudinal length of the axle plate <NUM> without kinking or damaging the cable <NUM> or the coupling between the cable <NUM> and the sensor device <NUM>.

As shown in <FIG>, <FIG>, and <FIG>, the first cover plate <NUM> is coupled to the outer surface <NUM>-<NUM> of the first side member <NUM>. In some examples, the first side member <NUM> may comprise a first recessed portion <NUM> that is designed to receive the first cover plate <NUM>. In some particular examples, a depth of the first recessed portion <NUM> may correspond to a thickness of the first cover plate <NUM> such that an outer surface <NUM>-<NUM> of the first cover plate <NUM> is flush with an adjacent portion of the outer surface <NUM>-<NUM> of the first side member <NUM> to avoid damage due to impacts. The first cover plate <NUM> covers and protects the sensor device <NUM> and the cable <NUM> from impacts and from contamination by foreign matter such as dirt, water, etc. The first cover plate <NUM> comprises openings 420A, 420B that extend through a thickness of the first cover plate <NUM> and are concentric with the openings 400A, 400B formed in the first side member <NUM> and the bores 144A, 144B, 146A, 146B formed in the axle plates <NUM>, <NUM>. A diameter of the openings 420A, 420B is greater than the diameter of any portion of the axles <NUM>, <NUM> such that the axles <NUM>, <NUM> may be inserted and removed without removing the first cover plate <NUM>, as described below.

The second side member <NUM> is coupled to the support structure <NUM> and is positioned adjacent to the first side member <NUM>. The second side member <NUM> comprises a second cable guide <NUM> that receives the cable <NUM> extending from the first side member <NUM>, as shown in <FIG> and <FIG>. The second cable guide <NUM> may be defined, for example, between two ridges or raised portions <NUM> formed on an outer surface <NUM>-<NUM> of the second side member <NUM>. The second cable guide <NUM> may comprise a first section <NUM>-<NUM> that extends along a longitudinal length of the support structure <NUM>, and a second section <NUM>-<NUM> that extends substantially perpendicular to the first section <NUM>-<NUM> and extends below the support structure <NUM>. A distance between the raised portions <NUM> may be varied such that the cable <NUM> is able to bend approximately <NUM> degrees without kinking or damaging the cable <NUM>, as shown in <FIG> and <FIG>. The second side member <NUM> may be coupled to the support structure <NUM> via a flange <NUM> that extends above the second cable guide <NUM> and is substantially perpendicular to a main body (not separately labeled) of the second side member <NUM>. The flange <NUM> comprises apertures <NUM> that extend through a thickness of the flange <NUM>. Fasteners <NUM>, which may comprise screws, bolts, or other suitable fasteners, extend through the apertures <NUM> in the flange <NUM> and are received in corresponding blind or tapped bores 143A formed in the upper surface <NUM>-<NUM> of the support structure <NUM>. Thus, the second side member <NUM> is coupled to the support structure <NUM> such that the main body comprising the second cable guide <NUM> extends along a sidewall <NUM>-<NUM> of the support structure <NUM>. As shown in <FIG> and <FIG>, the flange <NUM> may abut the torque arm <NUM> such that the apertures <NUM> formed in the flange <NUM> may serve as a drill guide for forming the bores 143A in the upper surface <NUM>-<NUM> of the support structure <NUM>, particularly for purposes of retrofitting existing vehicles with sensor devices <NUM>.

The second cover plate <NUM> may be coupled to the outer surface <NUM>-<NUM> of the second side member <NUM>, e.g., to the raised portions <NUM>, such that the second cover plate <NUM> covers and protects the cable <NUM>. In some configurations, as shown in <FIG> and <FIG>, there may be a gap between the first and second side members <NUM>, <NUM>, and the second cover plate <NUM> may extend across the gap and abut the first cover plate <NUM> to cover the exposed portion of the cable <NUM>. In some examples, the second cover plate <NUM> may comprise an extension <NUM> that projects from a corner of the second cover plate <NUM> toward the first cover plate <NUM>, as shown in <FIG> and <FIG>. The outer surface <NUM>-<NUM> of the first side member <NUM> may comprise a corresponding second recessed portion <NUM> that receives the extension <NUM> of the second cover plate <NUM>, and the first cover plate <NUM> may comprise a notch <NUM> corresponding to the extension <NUM>. The extension <NUM> may be used to help properly position the second cover plate <NUM> with respect to the first side member <NUM> and the first cover plate <NUM> and to prevent pivoting of the first side member <NUM> and the first cover plate <NUM> during installation, as described below. The extension <NUM> may also help to bridge the gap between the first and second side members <NUM>, <NUM>.

A height of the raised portions <NUM> of the second side member <NUM> and/or a thickness of the second cover plate <NUM> may be varied such that respective outer surfaces <NUM>-<NUM>, <NUM>-<NUM> of the first and second cover plates <NUM>, <NUM> are flush with each other and form a substantially continuous surface extending from a forward end of the outrigger arm assembly <NUM> toward the mast assembly <NUM>, as shown in <FIG>, <FIG>, and <FIG>. For example, as best seen in <FIG> and <FIG>, the support structure <NUM> may be wider than axle plates <NUM>, <NUM>, and the height of the raised portions <NUM> and/or the thickness of the second cover plate <NUM> may be varied to account for this difference in width between the support structure <NUM> and the axle plates <NUM>, <NUM>. In addition, a depth of the second recessed portion <NUM> may be varied to take into account the height of the raised portions <NUM> and/or the thickness of the second cover plate <NUM> so that the outer surfaces <NUM>-<NUM>, <NUM>-<NUM> of the first and second cover plates <NUM>, <NUM> are flush with each other.

An alternative configuration of the second side member <NUM>' is depicted in <FIG>. The outrigger arm assembly <NUM> depicted in <FIG> may be substantially similar in structure to the outrigger arm assembly <NUM> depicted in <FIG>, <FIG>, <FIG>, and <FIG>. Some components are removed and labeling of some components is eliminated in <FIG> to illustrate other aspects of the invention in detail. The outrigger arm assembly <NUM> comprises a first side member <NUM> coupled to an axle plate <NUM>, a first cover plate <NUM> coupled to the first side member <NUM>, and a second side member <NUM>' coupled to the support structure <NUM> adjacent to the first side member <NUM>. A second cover plate (not shown; see reference numeral <NUM> in <FIG> and <FIG>) may be coupled to the second side member <NUM>' as described herein. A cable guide member <NUM> extends between the support structure <NUM> and a support member (not labeled; see reference numeral <NUM> in <FIG> and <FIG>).

As described in detail herein, the first side member <NUM> receives a sensor device <NUM>, and the first and second side members <NUM>, <NUM>' and the cable guide member <NUM> receive a cable <NUM> extending from the sensor device <NUM> toward the mast assembly <NUM>. The side members <NUM>, <NUM>' protect the cable <NUM> and may isolate the cable <NUM> from contact with the axle plate <NUM> and the support structure <NUM>. With reference to <FIG>, the second side member <NUM>' comprises a second cable guide <NUM>' that receives the cable <NUM> extending from the first side member <NUM>. The second cable guide <NUM>' may comprise a channel that is formed in an outer surface <NUM>-<NUM>' of the second side member <NUM>'. The second cable guide <NUM>' may comprise a first section <NUM>-<NUM>' that extends along a longitudinal length of the support structure <NUM>, and a second section <NUM>-<NUM>' that extends substantially perpendicular to the first section <NUM>-<NUM>' and extends below the support structure <NUM>. The second side member <NUM>' may be coupled to the support structure <NUM> via fasteners <NUM>', which extend through apertures <NUM>' formed in the second side member <NUM>' and are received in corresponding blind or tapped bores 143B formed in a sidewall <NUM>-<NUM> of the support structure <NUM>. In particular, the first section <NUM>-<NUM>' of the second cable guide <NUM>' may comprise cutouts 432A' extending above or below the second cable guide <NUM>', and the apertures <NUM>' may be formed in the cutouts 432A' so that the fasteners <NUM>' do not interfere with the cable <NUM>. The fasteners <NUM>' may comprise screws, bolts, or other suitable fasteners.

As shown in <FIG>, the second side member <NUM>' may comprise two separate portions including a main body <NUM>', which comprises the second cable guide <NUM>', and a flange <NUM>'. The main body <NUM>' of the second side member <NUM>' extends along the sidewall <NUM>-<NUM> of the support structure <NUM>. The flange <NUM>' is located on an upper surface <NUM>-<NUM> of the support structure <NUM> and is substantially perpendicular to the main body <NUM>' of the second side member <NUM>'. The second side member <NUM>' may comprise a plurality of teeth 430A' that interlock or mesh with a plurality of corresponding teeth 436A' formed on the flange <NUM>'. The flange <NUM>' may be welded or otherwise fixedly coupled to the upper surface <NUM>-<NUM> of the support structure <NUM>. The main body <NUM>' of the second side member <NUM>' and the flange <NUM>' may be welded or otherwise fixedly coupled to each other at a joint formed by the teeth 430A', 436A', and the main body <NUM>' may be coupled to the sidewall <NUM>-<NUM> of the support structure <NUM> via the fasteners <NUM>'. As seen in <FIG>, the flange <NUM>' may abut the torque arm <NUM>, and the interlocking of the teeth 430A', 436A' may assist with proper positioning of the main body <NUM>' of the second side member <NUM>'. Thus, the apertures <NUM>' formed in the second cable guide <NUM>' may serve as a drill guide for forming the bores 143B in the sidewall <NUM>-<NUM> of the support structure <NUM>, particularly for purposes of retrofitting existing vehicles with sensor devices <NUM>. As described herein, the second cover plate (not shown; see <FIG>) may be coupled to the outer surface <NUM>-<NUM>' of the second side member <NUM>', e.g., via fasteners (not shown; see <FIG>) received in apertures <NUM>' formed in the second side member <NUM>'.

With reference to <FIG>, <FIG>, and <FIG>, the cable guide member <NUM> comprises a third cable guide <NUM> that receives the portion of the cable <NUM> extending from the second side member <NUM>, <NUM>'. The cable guide member <NUM> may be coupled at one end to a portion of the second side member <NUM>, <NUM>' that extends below the support structure <NUM>, e.g., the second section <NUM>-<NUM>, <NUM>-<NUM>' of the second cable guide <NUM>, <NUM>'. In particular, as shown in <FIG>, the cable guide member <NUM> comprises a flange <NUM> with apertures <NUM> formed through a thickness of the flange <NUM>. Fasteners <NUM>, which may comprise screws, bolts, or other suitable fasteners, extend through the apertures <NUM> in the flange <NUM> and are received in corresponding apertures <NUM>, <NUM>' formed in the second side member <NUM>, <NUM>', as shown in <FIG> and <FIG>. In some examples, the cable guide member <NUM> may comprise a substantially U-shaped structure defining the third cable guide <NUM>. The cable guide member <NUM> extends from the second side member <NUM>, <NUM>' to the support member <NUM>, which is located between the outrigger arm assemblies <NUM>, <NUM> and is coupled to the transverse plate <NUM> (see <FIG>). The support member <NUM> may comprise, for example, a bracket with an opening 116A formed in it. The cable guide member <NUM> may be coupled at its other end to the support member <NUM> via one or more fasteners (not labeled). The cable <NUM> extends from the cable guide member <NUM> toward the power unit (not shown; see reference numerals <NUM> and <NUM> in <FIG>) of the vehicle, where the cable <NUM> may join a cable harness (not shown) supported on the support member <NUM> and comprising one or more cables or wires coupled to a power supply <NUM> and a signal processor <NUM>, as described herein.

With reference to <FIG> and <FIG>, the first side member <NUM> may be mounted onto the axle plate <NUM> by inserting the first ends 140A, 142A of the axles <NUM>, <NUM> through the respective openings 400A, 400B of the first side member <NUM> and securing the axles <NUM>, <NUM> to the axle plate <NUM> as described herein. The second side member <NUM> is coupled to the support structure <NUM> via the fasteners <NUM>. The cable guide member <NUM> is coupled at one end to the second side member <NUM> via the fasteners <NUM> and at the other end to the support member <NUM>. The sensor device <NUM> may then be inserted into the opening <NUM> formed in the first side member <NUM> and coupled to the axle plate <NUM> via the fastener <NUM> such that the portion 300B of the housing <NUM> of the sensor device <NUM> extends through the bore <NUM> formed in the axle plate <NUM>. The cable <NUM> is placed in the first, second, and third cable guides <NUM>, <NUM>, <NUM> respectively formed in the first side member <NUM>, the second side member <NUM>, and the cable guide member <NUM>. The first cover plate <NUM> is coupled to the first side member <NUM> over the sensor device <NUM> and the cable <NUM> by inserting fasteners <NUM> through apertures <NUM> formed in the first cover plate <NUM>. The fasteners <NUM>, which may comprise screws, bolts, or other suitable fasteners, are received in corresponding apertures <NUM> formed in the first side member <NUM>. The second cover plate <NUM> is coupled to the second side member <NUM> over the cable <NUM> by inserting fasteners <NUM> through apertures <NUM> formed in the second cover plate <NUM>. The fasteners <NUM>, which may comprise screws, bolts, or other suitable fasteners, are received in corresponding apertures <NUM> formed in the second side member <NUM>. In some examples, the second cover plate <NUM> may also be coupled to the first side member <NUM> via the extension <NUM>. A fastener <NUM>, which may comprise a screw, a bolt, or other suitable type of fastener, is inserted through an aperture <NUM> formed in the extension <NUM>, and the fastener <NUM> is received in a corresponding aperture <NUM> formed in the second recessed portion <NUM> of the first side member <NUM>. The axles <NUM>, <NUM>, the first side member <NUM>, the first cover plate <NUM>, the second side member <NUM>', and the second cover plate (not shown) in <FIG> may be assembled in a similar manner.

The axles <NUM>, <NUM> may be removed and/or replaced after the installation of the side members <NUM>, <NUM>, <NUM>', sensor device <NUM>, and cover plates <NUM>, <NUM> without disturbing the sensor device <NUM> or requiring removal of the first side member <NUM> or the first cover plate <NUM>. Because the diameter of the openings 420A, 420B in the first cover plate <NUM> is larger than the diameter of any portion of the axles <NUM>, <NUM>, the axles <NUM>, <NUM> may be accessed and inserted or removed through the openings 420A, 420B of the installed first cover plate <NUM> and through the openings 400A, 400B of the installed first side member <NUM>. The axles <NUM>, <NUM> may then be secured to the axle plate <NUM> as described herein.

Typically, the axles <NUM>, <NUM> would be removed one at a time so that one axle <NUM>, <NUM> remains in place, which keeps the first side member <NUM> and the first cover plate <NUM> in place. In addition, the coupling of the second cover plate <NUM> to the first side member <NUM> via the extension <NUM> serves as a second attachment point between the frame member <NUM> and the first side member <NUM> and the first cover plate <NUM>, which helps to prevent unwanted pivoting of the first side member <NUM> and/or the first cover plate <NUM> following removal of one of the axles <NUM>, <NUM>. The sensor device <NUM> may be accessed by removing one or both of the cover plates <NUM>, <NUM> without the need to remove the side members <NUM>, <NUM>, <NUM>' or the axles <NUM>, <NUM>.

An alternative configuration of an outrigger arm assembly <NUM> is depicted in <FIG>. Unless otherwise noted, the outrigger arm assembly <NUM> depicted in <FIG> may be substantially similar in structure to the outrigger arm assembly <NUM> described herein. Some components are removed and labeling of some components is eliminated in <FIG> to illustrate other aspects of the invention in detail. The outrigger arm assembly <NUM> comprises a frame member <NUM> comprising a support structure <NUM> and a pair of axle plates <NUM>, <NUM>; a first side member <NUM> coupled to the axle plate <NUM>; a first cover plate <NUM> coupled to the first side member <NUM>; a second side member <NUM> coupled to the support structure <NUM> adjacent to the first side member <NUM>; and a second cover plate <NUM> coupled to the second side member <NUM>.

The first side member <NUM> in <FIG> may comprise openings (not labeled) that receive axles <NUM>, <NUM>. The axles <NUM>, <NUM> may be fixed to the axle plates <NUM>, <NUM>, and the first side member <NUM> may be coupled to the axle plate <NUM> via the axles <NUM>, <NUM>, as described herein. Wheels <NUM>, <NUM> may be rotatably mounted to and supported on a respective one of the axles <NUM>, <NUM>, and a code ring (not shown) may be fixed to, for example, the wheel <NUM>, as described herein. The second side member <NUM> in <FIG> may be coupled to the support structure <NUM> via fasteners <NUM>, which may comprise screws, bolts, or other suitable fasteners. Unlike the second side members <NUM>, <NUM>' in <FIG> and <FIG>, the second side member <NUM> in <FIG> does not include a flange extending over an outer surface (not labeled) of the support structure <NUM>. In addition, the second side member <NUM> comprises a chamfer <NUM> to allow clearance for adjacent components and/or structures. For example, the chamfer <NUM> may provide clearance for the weld between the mast rail 112A and the torque arm <NUM> so that the second side member <NUM> does not contact the weld and fits flush against a sidewall (not labeled) of the support structure <NUM>.

The first side member <NUM> receives a sensor device <NUM> and comprises a first cable guide <NUM> that receives a cable <NUM> extending from the sensor device <NUM>. The second side member <NUM> comprises a second cable guide <NUM>, which receives the cable <NUM> extending from the first side member <NUM>. A cable guide member (not shown; see reference numeral <NUM> in <FIG> and <FIG>) extends between the support structure <NUM> and a support member (not labeled; see reference numeral <NUM> in <FIG> and <FIG>) and receives the cable <NUM> extending from the second side member <NUM>.

With continued reference to <FIG>, the first cover plate <NUM> is coupled to the first side member <NUM> over the sensor device <NUM> and the cable <NUM> by inserting fasteners <NUM> through apertures <NUM> formed in the first cover plate <NUM>. The second cover plate <NUM> is coupled to the second side member <NUM> over the cable <NUM> by inserting fasteners <NUM> through apertures <NUM> formed in the second cover plate <NUM>. The fasteners <NUM>, <NUM> may comprise screws, bolts, or other suitable fasteners and are received in corresponding apertures (not labeled) formed in a respective one of the first or second side member <NUM>, <NUM>.

Similar to the first cover plates <NUM>, <NUM>' in <FIG> and <FIG>, the first cover plate <NUM> in <FIG> may comprise openings 1420A, 1420B extending through a thickness of the first cover plate <NUM> that allow the axles <NUM>, <NUM> to be inserted and removed without removing the first cover plate <NUM>, as described herein. The first side member <NUM> may comprise a recessed portion (not labeled) that is designed to receive the first cover plate <NUM>. Unlike the first cover plates <NUM>, <NUM>', the first cover plate <NUM> is substantially rectangular and lacks a notch. The second cover plate <NUM> may extend across a gap between the first and second side members <NUM>, <NUM> and may abut the first cover plate <NUM> to cover the exposed portion of the cable <NUM>. The second cover plate <NUM> may optionally comprise an extension <NUM> that extends from a corner of the second cover plate <NUM>. Unlike the extension <NUM> on the second cover plate <NUM> in <FIG>, the extension <NUM> in <FIG> is not attached to the first side member <NUM>. In addition, because the first cover plate <NUM> is substantially rectangular, the extension <NUM> projects downward and does not extend toward the first cover plate <NUM>. The extension <NUM> may substantially correspond to a shape of an adjacent portion of the support structure <NUM> and the axle plate <NUM>. As described herein, a thickness of the side members <NUM>, <NUM>, a depth of the recessed portion formed in the first side member <NUM>, and/or a thickness of the cover plates <NUM>, <NUM> may be varied, such that respective outer surfaces (not labeled) of the cover plates <NUM>, <NUM> are flush with each other, such that the outer surfaces of the cover plates <NUM>, <NUM> form a substantially continuous surface extending from a forward end of the outrigger arm assembly <NUM> toward the mast assembly <NUM> (see <FIG>).

In all examples described herein, the sensor device <NUM> is located adjacent to the wheel <NUM>, and more specifically to the code ring <NUM>, to sense movement of the code ring <NUM> and generate an output signal indicative of movement of the wheel <NUM>, as described herein. As shown in <FIG>, <FIG>, <FIG>, <FIG>, <FIG>, and <FIG>, the sensor device <NUM> is located such that the portion 300B extending through the axle plate <NUM> is adjacent to and aligned with the code ring <NUM> located within the wheel recess <NUM> of the wheel <NUM>. An air gap G is defined between the code ring <NUM> and the outermost surface of the portion 300B of the housing <NUM> of the sensor device <NUM> extending through the axle plate <NUM>, as shown in <FIG>. The air gap G may comprise, for example, about <NUM> inches to about <NUM> inches.

The sensor device <NUM> may comprise one or more sensors or switches for sensing the magnetic fields generated by the alternating N and S poles of the code ring <NUM> and generating a corresponding output signal <NUM> that is indicative of movement of the wheel <NUM>. In some examples, the sensor device <NUM> may comprise a single Hall-effect sensor, e.g., a bipolar Hall-effect sensor. In other examples, the sensor device <NUM> may comprise two or more Hall-effect sensors. In some particular examples, the sensor device <NUM> may comprise a dual-channel sensor (e.g., Channel A and Channel B) comprising two Hall-effect sensors that are contained within the same housing <NUM>. The one or more Hall-effect sensors may be located in the portion 300B of the housing <NUM> of the sensor device <NUM> that extends through the axle plate <NUM>. In particular, the sensing elements located in the portion 300B of the housing <NUM> of the sensor device <NUM> may comprise the one or more Hall-effect sensors and circuitry to detect the magnetic fields generated by the code ring <NUM>. A dual-channel sensor (e.g., Channel A and Channel B) comprising two Hall-effect sensors is commercially available from Phoenix America, Inc. (Fort Wayne, IN).

With reference to <FIG> and <FIG>, the sensor device <NUM> is coupled to a power supply <NUM> located on the power unit <NUM>, <NUM> that provides an input voltage signal <NUM> such as a regulated input voltage. As the wheel <NUM> rotates, the code ring <NUM> located within the wheel recess <NUM> also rotates. A voltage of the output signal <NUM> generated by the sensor device <NUM> changes based on whether a N or a S pole is passing by the portion 300B of the housing <NUM> of the sensor device <NUM> extending through the axle plate <NUM> adjacent to the code ring <NUM>. A signal processor <NUM>, located on the power unit <NUM>, <NUM>, receives the output signal(s) <NUM> from the sensor device <NUM> in the form of one or more square wave signals. The power supply <NUM> and signal processor <NUM> may be positioned in separate locations or may comprise a single module. In the case of a sensor device <NUM> with one Hall-effect sensor, a rotational speed of the wheel <NUM> may be determined by the signal processor <NUM> based on the number of cycles or pulses in the output signal <NUM> counted per sampling period, e.g., the number of North or South poles counted per unit time or the number of both North and South poles counted per unit time. In the case of a sensor device <NUM> with two Hall-effect sensors, the output signals <NUM>, e.g., signals A and B, are phase shifted by <NUM> degrees from each other, i.e., <NUM> degrees out of phase with one another, to generate a quadrature output. The quadrature output may be used by the signal processor <NUM> to determine the rotational speed of the wheel <NUM> as described above, i.e., based on the number of cycles or pulses in the output signal from one of the Hall-effect sensors counted per sampling period, and, further, using the relative phase of the output signals <NUM> produced by the two channels, a direction of rotation of the code ring <NUM> may be determined based on which signal (i.e., signal A or signal B) is leading the other. Acceleration values may be calculated by the signal processor <NUM> by taking derivatives of the speed values.

The signal processor <NUM> may comprise any control module on the vehicle <NUM>, <NUM>. In some examples, the signal processor <NUM> comprises an RFID module that may be used in conjunction with one or more geolocation-based assistance and control features. For example, tags or other markers located in or on the floor surface F or other structure may designate various zones, such as zones with speed and/or lift height restrictions and/or an auto-hoist zone in which an Automatic Positioning System automatically lowers or raises the forks <NUM>, <NUM> to a desired height based on the location of the vehicle <NUM>, <NUM> with respect to a pick location. The signal processor <NUM> comprising the RFID module may use the output signal <NUM> of the sensor device <NUM>, in conjunction with a tag reader (not shown), to determine a current speed and location of the vehicle <NUM>, <NUM> within a workspace. In all examples, the signal processor <NUM> may be communicatively coupled to a controller area network (CAN) bus and may provide information to other controllers in the vehicle <NUM>, <NUM>.

Alternatively, or in addition, the other outrigger arm assembly <NUM> (see <FIG>, <FIG>, and <FIG>) may comprise a sensor device that is substantially similar to the sensor device <NUM> described herein with respect to the outrigger arm assembly <NUM> and <NUM>. For example, a sensor device (not shown) may be coupled to an outer surface (not separately labeled) of the inner axle plate <NUM> adjacent to the wheel <NUM>, and the wheel <NUM> may comprise a code ring located in a wheel recess. One or more side members (not shown) may be coupled to an outer surface (not visible) of the axle plate <NUM> to enclose and/or support the sensor device. In general, the sensor device(s) <NUM> and code ring(s) <NUM> will be located in conjunction with the outer or forward wheel(s), e.g., wheels <NUM> and/or <NUM>. The inner wheels <NUM>, <NUM> may lose contact with the floor surface F due, for example, to a heavy load on the forks <NUM>, <NUM> or an uneven floor surface, which may cause inaccurate readings.

In configurations in which two or more sensor devices <NUM> are present in a single vehicle <NUM>, <NUM>, each sensor device <NUM> may serve as a check on the other sensor device(s) <NUM>. For example, the speeds calculated based on the respective output signals of the sensor devices <NUM> may be compared, and if a difference between the calculated speeds exceeds a predetermined threshold, one or more of the sensor devices <NUM> may be malfunctioning. In other configurations, the vehicle <NUM>, <NUM> may comprise an encoder (not shown) that is coupled to a traction motor shaft (not shown) and that generates signals indicative of the speed, acceleration, and/or direction of rotation of the traction motor. If a difference in the calculated speed, acceleration, and/or direction of rotation exceeds a predetermined threshold, there may be a malfunction. In some examples, an error message may be displayed to an operator of the vehicle <NUM>, <NUM>. In other examples, one or more functions of the vehicle <NUM>, <NUM> may be restricted or disabled. For example, the speed of the vehicle may be restricted and/or the fork lowering/raising function may be restricted or disabled.

The presently disclosed sensor device <NUM> provides a number of benefits and advantages over existing devices and systems for determining the speed of a vehicle based on a rotational speed of the wheel or other component of the vehicle. For example, many existing systems utilize a sensor associated with a complex bearing assembly that adds weight and is subject to a significant amount of wear. A significant amount of time and labor is typically required to disassemble and reassemble the bearing assembly to access the sensor and to repair or replace components of the bearing assembly. Further, when the bearing assembly is replaced because of bearing wear, the sensor, which can be relatively expensive, must be replaced as well when the sensor is formed as part of the bearing assembly.

The sensor device <NUM> in accordance with the present disclosure is small and can be accessed by removing either the side member <NUM> in the configuration depicted in <FIG>, <FIG>, <FIG>, and <FIG> or the cover plates <NUM>, <NUM> in the configuration depicted in <FIG> (see also <FIG> and <FIG>). The sensor device <NUM> is located such that components that wear out quickly, e.g., the wheel bearings 133A, 133B, 135A, 135B, the wheel covers 132B, 134B (which typically results in the wheels <NUM>, <NUM> being replaced), and/or the axles <NUM>, <NUM>, may be repaired or replaced without disturbing or replacing the sensor device <NUM>. The code ring <NUM>, which is relatively inexpensive, may be replaced frequently, e.g., each time the wheels <NUM>, <NUM> and/or axles <NUM>, <NUM> are replaced. The bores 143A, 143B, <NUM>, <NUM> drilled into and/or through the support structure <NUM> and the axle plate <NUM> have a small enough diameter that the structural integrity of the support structure <NUM> and the axle plate <NUM> remains substantially unchanged, and the location of the sensor device <NUM> and bores 143A, 143B, <NUM>, <NUM> allows existing vehicles to be retrofitted relatively easily, particularly when used in conjunction with a side member <NUM> comprising auxiliary bores <NUM>, as shown in <FIG>, or a second side member <NUM>, <NUM>' comprising apertures <NUM>, <NUM>', as shown in <FIG> and <FIG>, that may serve as drill guides.

In addition, conventional, bearing-style sensor systems must typically conform to very tight tolerances in order to provide accurate readings. Rather than directly detecting the rotational speed of the wheel, the sensor incorporated into a bearing assembly generally monitors the speed of a ring that is coupled to an inner, rotating portion of the bearing. Typically, the axle is press-fitted tightly within the inner rotating portion of the bearing to prevent the axle from slipping relative to the inner portion of the bearing. A wheel is fixed to the axle so as to rotate with the axle. If there is any slippage or rotation between the axle and the inner portion of the bearing, the wheel speed provided by the sensor will not be accurate as the sensed ring will rotate at a different rate from the axle and the wheel. As a result, sensor/bearing assemblies typically must be precisely machined and press-fitted tightly onto the axle to ensure that the axle does not slip relative to the inner portion of the bearing, i.e., so that the axle rotates at the same rate as the bearing inner portion and the ring. However, effecting a very tight press fit between an axle and a bearing to ensure no rotation between the axle and the bearing is more involved, e.g., takes more time and requires tighter tolerances. In the present invention, because some slight rotation between the axle <NUM> and the wheel bearings 133A, 133B will not affect the accuracy of the readings provided by the sensor device <NUM>, the wheel bearings 133A, 133B do not have to be tightly mounted to the axle <NUM>, making replacement of the wheel <NUM> in the field easier and more efficient.

In the prior art, press-fitting also ensures that the air gap between the sensor and the ring is maintained at the precise and consistent value required to achieve accurate readings. A tightly controlled and consistent air gap is particularly critical for gear-tooth or proximity sensors, and any increase in the air gap size generally requires an increase in sensor size.

In contrast, the presently disclosed sensor device <NUM> directly monitors the wheel speed, such that inconsistent rotation or slippage of the axle <NUM> relative to the wheel bearings 133A, 133B does not affect the accuracy of the readings provided by the sensor device <NUM>. Because the wheel speed is directly monitored, the wheel may be a driven wheel or a non-driven wheel as described herein, which does not involve a rotating axle. The presently disclosed sensor device <NUM> provides similar advantages over conventional sensor devices that determine the vehicle speed based on a rotational speed or position of another component of the vehicle, such as the shaft of the traction motor. In particular, encoders that monitor a speed and position of the traction motor shaft may provide inaccurate readings of an actual vehicle speed, particularly when driven wheel slip is occurring. Because the presently disclosed sensor device <NUM> directly monitors the wheel speed of a non-driven wheel, the actual vehicle speed may be more accurately determined.

The presently disclosed sensor device <NUM> is also less likely to be affected by the high degree of variability in the air gap created by differences and/or inconsistencies in the structure and dimensions of the outrigger arm assemblies <NUM>, <NUM>. For example, Hall-effect sensors, in combination with a magnetic target (e.g., the code ring <NUM>) are much more sensitive and are typically effective over a much wider air gap range, as compared to, for example, an inductive proximity sensor or a back biased Hall sensor. As a result, the presently disclosed sensor device <NUM> may be a more robust solution and may be more quickly assembled by hand.

Claim 1:
A wheel assembly (<NUM>) including a sensor for measuring wheel movement comprising:
a frame member (<NUM>);
an axle (<NUM>) fixed to the frame member (<NUM>);
a wheel (<NUM>) rotatably mounted to the axle (<NUM>), wherein the wheel (<NUM>) comprises a wheel recess (<NUM>);
a code ring (<NUM>) located within the wheel recess (<NUM>) for rotation with the wheel (<NUM>); and
a sensor device (<NUM>) coupled to the frame member (<NUM>) and located adjacent to the code ring (<NUM>), wherein the sensor device (<NUM>) senses movement of the code ring (<NUM>) and generates an output signal indicative of the wheel movement;
wherein the frame member (<NUM>) comprises opposing axle plates (<NUM>, <NUM>) for supporting the axle (<NUM>), each of the opposing axle plates (<NUM>, <NUM>) comprising a bore (144A, 146A) formed therethrough for receiving the axle (<NUM>);
one of the opposing axle plates (<NUM>, <NUM>) comprises a further bore (<NUM>) through which a portion of the sensor device (<NUM>) at least partially extends; and
the wheel assembly (<NUM>) further comprises a side member (<NUM>, <NUM>) that is coupled to the one axle plate (<NUM>, <NUM>) and comprises a cavity (<NUM>), or an opening (<NUM>), that receives and at least partially encloses the sensor device (<NUM>).