Wireless Forklift Height Encoder

The object of this project is to create a wireless system for accurately measuring the extension of a forklift. This measurement will be used by the operator to easily and accurately return to a given shelf height. It can also be used to implement new control methods, such as entering a numeric height, or having buttons with preset height values. This sensor will essentially take the guesswork out of forklift operation.

This project is sponsored by Hyster-Yale Group, who design and manufacture forklifts in the Portland, OR, area.

Problem Definition
Background Hyster-Yale Group would like to incorporate a forklift height encoder in their products to improve usability as well as to incorporate autonomous operations. The problem with current height sensor designs is either cost, resolution, or durability. In order to meet these requirements, a small, wireless package that mounts on the mast of the forklift must be designed. This requires wireless data transfer as well as energy harvesting for long term, maintenance free operation.

Design Goals and Deliverables Select an appropriate sensing method Wirelessly transmit data to a receiver Harvest energy to allow sensor to run indefinitely Design a package that meets the sizing criteria

Specifications Ideal Measurements Size: 64mm x 90mm x 18mm Sampling Rate: 400Hz Measurement Resolution: 2mm Measurement Height: 7m