(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2006/0226675 A1
`Dunn
`(43) Pub. Date:
`Oct. 12, 2006
`
`US 20060226675A1
`
`(54) PEDALS AND FLOOR MAT
`CONFIGURATION FOR AN INDUSTRIAL
`VEHICLE
`
`Related U.S. Application Data
`(60) Provisional application No. 60/669,744, filed on Apr.
`8, 2005.
`
`(75) Inventor: Colin F. Dunn, (US)
`
`Publication Classification
`
`Correspondence Address:
`MARGER JOHNSON & MCCOLLOM, P.C.
`
`(51) Int. Cl.
`B60N 3/06
`(52) U.S. Cl
`
`(2006.01)
`
`296/75
`
`210 SW MORRISON STREET, SUITE 400
`
`Oa -
`
`- - -
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`- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
`
`PORTLAND, OR 97204 (US)
`
`ABSTRACT
`(57)
`A presence detection system may include a pedal assembly
`(73) Assignee: NMHG OREGON, LLC, Portland, OR that is located underneath a vehicle floor. The pedal assem
`bly in one embodiment is recessed within the underside of
`a floor mat to eliminate trip hazards on the vehicle floor.
`Other embodiments may include a textured upper mat
`surface that provides traction, indicates the location of the
`recessed presence pedal and provide run-off for liquid spills.
`
`(21) Appl. No.:
`
`11/400,052
`
`(22) Filed:
`
`Apr. 7, 2006
`
`
`
` DGL Exhibit 1010
`Page 0001
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`Patent Application Publication Oct. 12,2006 Sheet 1 of 5
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`US 2006/0226675 Al
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`FIG. 1A
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`Page 0002
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`Patent Application Publication Oct. 12, 2006 Sheet 2 of 5
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`US 2006/0226675 A1
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` DGL Exhibit 1010
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`Patent Application Publication Oct. 12,2006 Sheet 3 of 5
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`US 2006/0226675 Al
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`FIG, 2
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`FIG. 3
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`DGL Exhibit 1010
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`Patent Application Publication Oct. 12, 2006 Sheet 4 of 5
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`US 2006/0226675 A1
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`FIG. 4
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`Patent Application Publication Oct. 12, 2006 Sheet 5 of 5
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`US 2006/0226675 A1
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`FIG. 6
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` DGL Exhibit 1010
`Page 0006
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`US 2006/0226675 A1
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`Oct. 12, 2006
`
`PEDALS AND FLOORMAT CONFIGURATION
`FOR AN INDUSTRIAL VEHICLE
`
`BACKGROUND
`0001. The invention relates to a presence detection sys
`tem used primarily in a vehicles such as an industrial pallet
`truck.
`0002 Industrial trucks, such as lift trucks, may include a
`cabin where an operator rides while driving the vehicle and
`may possibly include a forklift for carrying loads. The floor
`in some lift trucks may be fitted with a presence pedal. The
`presence pedal is alternatively referred to as a "dead man
`switch'. The presence pedal or dead man switch disables
`certain truck operations when the operator is not in a normal
`operating position in the cabin. For example, the vehicle
`may not start or move until the operator stands on the
`presence pedal. This can be used as a safety feature that
`shuts off the vehicle if the operator happens to fall out of the
`lift truck cabin.
`0003 Current presence pedals currently extend up out of
`the floor of the pallet truck cabin. This creates a trip point for
`the operator and also make it more difficult for the operator
`to move around in the cabin. Current presence pedals extend
`up through an opening in the cabin floor. Water, dirt, and
`other debris can fall through this opening and may disrupt or
`damage equipment located underneath the floor of the cabin.
`0004 The present invention addresses this and other
`problems associated with the prior art.
`
`SUMMARY OF THE INVENTION
`0005. A presence detection system may include a pedal
`assembly that is located underneath a vehicle floor. The
`pedal assembly in one embodiment is recessed within the
`underside of a floor mat to eliminate trip hazards on the
`vehicle floor. Other embodiments may include a textured
`upper mat Surface that provides traction, indicates the loca
`tion of the recessed presence pedal, and provide run-off for
`liquid spills.
`0006 The foregoing and other objects, features and
`advantages of the invention will become more readily appar
`ent from the following detailed description of a preferred
`embodiment of the invention which proceeds with reference
`to the accompanying drawings.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`0007 FIG. 1A shows a perspective view of a lift truck.
`0008 FIG. 1B shows a perspective view of an operator
`cabin of the lift truck that shows an operator standing on a
`presence detection system.
`0009 FIG. 2 shows the presence detection system in
`more detail.
`0010 FIG. 3 shows an exploded view of the presence
`detection system.
`0011
`FIG. 4 shows a perspective view of a pedal assem
`bly used in the presence detection system.
`0012 FIG. 5 shows an exploded view of the pedal
`assembly shown in FIG. 4.
`
`0013 FIG. 6 shows topside and underside views of a
`floor mat used in a presence detection system that includes
`two pedal assemblies.
`
`DETAILED DESCRIPTION
`0014 FIG. 1A shows a lift truck 10. The lift truck 10
`includes a cabin 12, main mast 15, auxiliary mast 14, and
`forks 9. The auxiliary mast 14 is mounted on the cabin 12.
`The cabin 12 and auxiliary mast 14 may be lifted and
`lowered on the main mast 15. The forks 9 may be lifted and
`lowered on the auxiliary mast 14.
`0015 FIG. 1B shows an operator 18 standing in a cabin
`12 of the lift truck 10. The cabin 12 includes a floor 20 that
`contains a presence detection system 22. The operator 18
`stands on a particular area of the presence detection system
`22 in order to operate the lift truck 10. For example, the lift
`truck 10 may not start until the operator 18 stands on a
`particular location of the presence detection system 22.
`Similarly, the lift truck 10 may stop if the operator steps out
`of the cabin 12 or steps off of the presence detection system
`22. In another example, the main mast 15 or auxiliary mast
`14 (FIG. 1A) may be disabled when the operator 18 is not
`standing on the presence detection system 22. In yet another
`example, an operator control 16 may be disabled when the
`operator 18 is not standing on the presence detection system
`22. Of course these are only examples of the different
`vehicle operations that may be disabled when the presence
`detection system 22 is not activated.
`0016. As will be described in more detail below, the
`presence detection system 22 includes a pedal 34 recessed
`within the underside of a floor mat 36 (FIG. 3) to eliminate
`trip hazards on the cabin floor 20. An upper mat surface is
`textured to provide grip, indicate the location of the recessed
`presence pedal, and provide run-off for liquid spills. While
`shown installed in a lift truck 10, it should also be under
`stood that the presence detection system 22 can be used in
`any vehicle that needs to either enable or disable vehicle
`operations based on the detected presence of a vehicle
`operator 18.
`0017 FIG. 2 shows the presence detection system 22 in
`an isolated view with the cabin 12 shown in a cutaway
`shadow view with dashed lines. FIG. 3 shows an exploded
`view of the same presence detection system 22. Referring to
`FIGS. 2 and 3, a pedal assembly 30 is fixed underneath the
`floor 20 of cabin 12. A lower pedal platform 44 extends up
`through a hole 42 in floor 20 and is attached to an upper
`pedal plate 34. A hinging assembly 46 retractably suspends
`the lower pedal platform 44 and upper pedal plate 34 above
`the floor 20. The floor 20 is rigidly attached to the cabin 12
`and supports the operator 18, pedal assembly 30, and a floor
`mat 36. The floor 20 may act as a down-stop for the upper
`pedal plate 34. Dampening and noise reduction are provided
`by sponge strips 32 bonded to the underside of the upper
`pedal plate 34. The pedal assembly 30 may alternatively be
`referred to as a “dead man switch'.
`0018. One embodiment of the floor mat 36 is made from
`a polyurethane material and sits on the cabin floor 20. The
`floor mat 36 is suspended above the cabin floor 20 by ribs
`51 that extend downward from a bottom side. One area of
`the bottom side of floor mat 36 does not include ribs 51 and
`thereby forms a cavity 48 that receives or contains the upper
`
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`Oct. 12, 2006
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`pedal plate 34. If required, the ribs 51 also allow passage of
`cabling between the floor mat 36 and floor 20.
`0.019 Channels 50 extend across a top surface of floor
`mat 36 and serve to direct any water or other fluids falling
`on the top surface outward towards the outside edges of the
`floor mat 36 away from a central location where the pedal
`assembly 30 is located. The floor mat 30 seats within a
`recess in floor 20 formed by a lip 52, and is held down on
`the sides by step plates 38.
`0020. The floor mat 36 further includes a sensing area 40
`that in one embodiment includes a textured or traction
`Surface that has a different Surface shape or design than the
`remainder of the top Surface. The design of the sensing area
`40 provides an indication of where the operator 18 needs to
`stand to depress upper pedal plate 34. The Surface design of
`sensing area 40 can also provide additional gripping for the
`foot of the operator 18 by providing for example, a pebbled,
`hatched, serrated, or other non-Smooth floor mat surface.
`0021 When an operator steps on sensing area 40, the
`floor mat 36 moves downward pressing against upper pedal
`plate 34. The pedal assembly 30 then retracts allowing both
`the upper pedal plate 34 and lower pedal platform 44 to
`move downward until a sensing unit 54 detects a proximity
`element 65. This sends a signal to an electrical controller 56
`that then enables vehicle operations that require the operator
`18 to be present in cabin 12 (FIG. 1B).
`0022. If the operator 18 steps off of sensing area 40, the
`pedal assembly 30 retracts causing both lower pedal plat
`form 44 and upper pedal plate 34 to move upwards into an
`elevated position inside cavity 48. The sensing unit 54 loses
`actuation with the proximity element 65 removing the
`actuation signal to controller 56. The controller 56 accord
`ingly disables the vehicle operations that required the opera
`tor 18 to be located on the sensing area 40.
`0023. It should be understood that actuators other than a
`pedal assembly 30 could also be used. For example, a
`plunger type button switch could be used that extends from
`the cabin floor 20. The cavity 48 in the floor mat 36 would
`then be adapted to the shape of the plunger switch. Further,
`there is also no requirement that a floor mat be used to cover
`the pedal assembly 30. Alternatively, a rubber epoxy or
`alternative water resistant cover may extend over the hole 42
`in floor 20. The rubber cover may seamlessly extend from
`the sides of the hole 42 over the top of a pedal plate 34 that
`is sized to fit inside of hole 42. The pedal plate 34, when
`depressed by the operator 18, may move into hole 42 and
`activate sensor 54. Alternatively, the upper pedal plate 34
`may never extend up from hole 42. In this embodiment, a
`domed rubber pad may extend from hole 42 and depress
`lower pedal platform 44 down underneath floor 20.
`0024 FIGS. 4 and 5 show the pedal assembly 30 in more
`detail. Two pivot members 72 and 74 are pivotally attached
`at one end to pivots 82 and 80, respectively, that extend from
`bracket 70. Opposite ends of pivot members 72 and 74 are
`also pivotally connected to pivots 78 and 76 on a flange 79
`that extends from the bottom of lower pedal platform 44.
`0.025
`FIG. 4 shows pedal assembly 30 in a raised con
`dition where a spring 67 pulls a bottom end of pivot member
`72 forward, in turn rotating the opposite end of pivot
`member 72 upwards, holding lower pedal platform 44 in the
`raised position. The pivot member 74 rotates upward in
`
`unison with pivot member 72 to keep the lower pedal
`platform 44 and attached upper pedal plate 34 in a Substan
`tially horizontal alignment when transitioning between the
`raised and lowered positions.
`0026.
`In the raised position, a proximity element 65 is
`spaced apart from an inductive sensor 54. The proximity
`element 65, for example, may be a magnet. The sensor 54
`may not generate a signal when this spacing exists between
`sensor 54 and proximity element 65. This non-signal indi
`cation is detected by controller 56 in FIG. 3 via conductors
`55. The non-signal causes the controller 56 to disable any of
`the vehicle operations that require the operator to be stand
`ing or stepping on pedal assembly 30.
`0027. When the upper pedal plate 34 and lower pedal
`platform 44 are depressed, the two pivot members 72 and 74
`rotate downwards causing the proximity element 65 to come
`within a sensing range of the sensor 54. Accordingly, the
`sensor 54 sends a presence signal over conductors 55 to the
`controller 56 that indicates operator presence. Software
`and/or hardware in the controller 56 then enable whatever
`vehicle operations require the operator to step down on
`pedal assembly 30.
`0028. Once released, the spring 67 pulls pivot member 72
`forward, raising the lower pedal platform 44 and upper pedal
`plate 34 back up into the cavity 48 (FIG. 3) in floor mat36.
`This simultaneously moves the proximity element 65 up
`away from sensor 54 disabling the presence signal and
`associated vehicle operations.
`0029. As mentioned above, the hinge mechanism that
`includes pivot members 72 and 74 and pivots 80, 82, 76, and
`78 constricts the surface of lower pedal platform 44 to
`remain horizontal and substantially parallel with floor 20
`while moving between the raised and lowered positions.
`This allows operation of the presence detection system 22
`when the upper pedal plate 34 is loaded at any surface
`location while still remaining underneath a relatively low
`profile cavity 48 in floor mat36. The geometry of the pedal
`assembly 30 is intended to provide a calculated resistance
`against the foot of the operator allowing the operator 18 to
`activate the presence detection system 22 while standing or
`in a seated position.
`0030) Non-metallic flanged bushings 69 and nylon wash
`ers 60 reduce friction losses in the hinging mechanism 46
`and prevent seizure when operated in cold storage applica
`tions. The distance between the sensor 54 and proximity
`element 65 while in the lowered position may be varied
`according to the sensitivity of the sensor 54 by turning a
`grub screw 61. The distance that the lower pedal platform 44
`is allowed to move downward in the depressed condition is
`adjusted by another grub screw 62. Both grub screws 61 and
`62 are adjustable from the cabin 12 when the pedal assembly
`30 is fitted in place.
`0031) Both grub screws 61 and 62 can be locked in place
`by turning screws 63 into opposite ends of receiving sleeves
`71A and 71B that have female threaded receptors on both a
`top and bottom end. Thus, the pedal assembly 30 is fully
`height and sensitivity-adjustable, and is Suitable for use in
`both conventional and cold storage applications.
`0032. The pedal assembly 30 may be used in either a
`single or dual pedal configuration. The single pedal con
`figuration is used, for example, when operator ingress and
`
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`egress may be restricted by a forward barrier. The dual pedal
`configuration may be used, for example, when the vehicle is
`fitted with the auxiliary mast 14 (FIG. 1A) and a trilateral
`attachment. The dual pedal configuration may require two
`pedal assemblies 30 to be depressed at the same time in
`order for the truck to be fully operational. When a single
`pedal configuration is used, the pedal assembly 30 might be
`located under a right hand pedal plate, as the operator 18
`faces the controls.
`0033 FIG. 6 shows one embodiment of a floor mat that
`may be used with the dual pedal configuration. The dual
`pedal configuration may arrange the position of the two
`pedal assemblies so that both pedals cannot be activated by
`one foot. In addition, the pedal assemblies may be arranged
`in such a manner that the foot of the operator 18 can not
`protrude beyond the leading edge of the cabin structure
`during operation and still press down both pedal assemblies
`3O.
`0034. In this embodiment, two separate pedal assemblies
`30 are located directly underneath presence areas 92 in the
`floor mat 90. The top side of floor mat 90 includes channels
`98 that both provide traction for the operator and also serve
`to direct water and any other fluids out away from the central
`sensing areas 92. The bottom side of floor mat 90 includes
`ribs 94 that suspend the top side up above the cabin floor 20
`(FIG. 2) and further define the cavities 96 that are sized to
`receive two associated upper pedal plates 34 (FIG. 3) while
`in the raised position.
`0035. The ribs 94 may be of differing heights and lengths.
`In one embodiment, the ribs 94 in the middle of floor mat 90
`may be higher than the ribs on the sides of floor mat 90. This
`creates a slightly domed shape on the top surface that further
`promotes the redirection of water toward the sides of floor
`mat 90. Further, the ends 100 of the ribs 94 next to the
`cavities 96 may have sloped sides that provide a graduated
`transgression to the non-ribbed cavities 96. This may pro
`vide more resilience and improve elasticity in the sensing
`areas 92.
`0036) The operator 18 (FIG. 1B) steps on the two pres
`ence areas 92 prior to starting some vehicle operation. The
`two presence areas 92 in mat 90 deflect downward under the
`weight of the operator 18 and accordingly depress the two
`pedal assemblies 30 located directly underneath. The two
`associated sensors 54 in the pedal assemblies 30 detect the
`associated proximity elements 65 (FIG. 4) and generate two
`associated presence signals. The controller 56 (FIG. 3),
`upon detecting the two presence signals, enables certain
`vehicle operations.
`0037 Again the floor mat 90 sits flush in the recess of the
`cabin floor 20 (FIG. 3). The pedal assemblies 30 sitcom
`pletely underneath the presence areas 92 in floor mat 90,
`thus removing any pedal that would protrude upwardly
`through the cabin floor that could trip or otherwise obstruct
`the movement of the operator 18 while operating the vehicle
`10.
`0038 Having described and illustrated the principles of
`the invention in a preferred embodiment thereof, it should be
`apparent that the invention may be modified in arrangement
`and detail without departing from Such principles. I claim all
`modifications and variation coming within the spirit and
`Scope of the following claims.
`
`1. A presence detection system, comprising:
`a detection device located on the floor of a vehicle that
`detects the presence of an operator in the vehicle when
`the operator depresses an actuator, and upon detection
`of the operator enabling vehicle operations that are
`disabled when the presence of the operator is not
`detected in the vehicle by the detection device,
`the detection device maintaining a position below or flush
`with a top surface of the floor while moving between a
`raised and lowered position.
`2. The presence detection system according to claim 1
`including a floor mat that extends over the actuator and
`includes at least one cavity in a bottom side for allowing the
`actuator to move between the raised position and the low
`ered position.
`3. The presence detection system according to claim 1
`wherein the actuator comprises a pedal that maintains a
`substantially horizontal alignment parallel with the vehicle
`floor while moving between the raised and lowered posi
`tions.
`4. The presence detection system according to claim 3
`including a sensor and proximity element, the sensor detect
`ing the proximity element when the pedal is depressed and
`generating an enable signal for enabling the vehicle opera
`tions.
`5. The presence detection system according to claim 4
`wherein the proximity element and/or sensor are adjustable
`to vary a distance between the proximity element and the
`sensor when the pedal is depressed.
`6. The presence detection system according to claim 3
`including an adjustable stop that varies how far the pedal can
`be moved downward when in a fully lowered position.
`7. The presence detection system according to claim 2
`including ribs that extend downward from a bottom side of
`the floor mat suspending the floor mat above the vehicle
`floor and further including non-ribbed areas on the bottom
`side of the floor mat that form the cavity that contains the
`actuatOr.
`8. The presence detection system according to claim 7
`wherein a top side of the floor mat includes a presence area
`that identifies the location of the cavity on the bottom side
`of the floor mat and that when depressed by the operator,
`moves the actuator into the lowered position.
`9. The presence detection system according to claim 8
`wherein the floor mat includes two operator presence areas,
`each located in positions where feet of the operator would
`normally be located when operating the vehicle.
`10. The presence detection system according to claim 2
`wherein a top side of the floor mat has a domed shape and
`channels that direct liquid out towards a perimeter of the
`floor mat.
`11. A method for detecting the presence of an operator in
`a vehicle, comprising:
`locating an actuator device on or near a floor of a vehicle
`for generating a presence signal when moved between
`a raised position and a lowered position by a vehicle
`operator,
`using the presence signal to enable vehicle operations that
`require the operator to be located in the vehicle; and
`arranging the actuator device on the vehicle floor so the
`actuator device does not extend above a top surface of
`the vehicle floor.
`
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`12. The method according to claim 11 including:
`using a floor mat as the top surface of the vehicle floor;
`suspending the floor mat above the vehicle floor; and
`including at least one cavity on a bottom side of the floor
`mat that fits over the actuator device.
`13. The method according to claim 12 including using ribs
`on a bottom side of the floor mat to suspend the floor mat
`above the vehicle floor and using at least one non-ribbed
`area on the bottom side of the floor mat to form a cavity that
`contains the actuator device.
`14. The method according to claim 13 including providing
`an area on a top side of the floor mat that identifies where the
`cavity is located on the bottom side of the floor mat.
`15. The method according to claim 12 sizing the ribs to
`create a domed top surface on the floor mat.
`16. The method according to claim 111 including:
`attaching a foot pedal to the actuator device;
`maintaining the foot pedal in a Substantially horizontal
`position parallel with the vehicle floor while the foot
`pedal moves between the raised and lowered positions.
`17. The method according to claim 11 including:
`using a sensor underneath the vehicle floor to generate the
`presence signal;
`using a proximity element to notify the sensor when the
`actuator device is in the lowered position; and
`
`adjusting a distance between the sensor and the proximity
`element when the actuator device is in the lowered
`position.
`18. A system for monitoring the presence of an operator
`in a lift truck, comprising:
`a lift truck floor that is used for Supporting an operator
`while the operator operates the lift truck; and
`a pedal assembly attached to the lift truck floor that
`enables one or more lift truck operations when the
`operator moves the pedal assembly between a raised
`position and a lowered position, the pedal assembly
`maintaining a position either flush or below a top
`surface of the lift truck floor in both the raised and
`lowered position.
`19. The system according to claim 18 wherein the top
`surface of the lift truck floor includes a floor mat that is
`Suspended above the pedal assembly.
`20. The system according to claim 19 including:
`ribs on a bottom side of the floor mat that suspend the
`floor mat over the pedal assembly; and
`a non-ribbed area on the bottom side of the floor mat that
`contains a top pedal plate of the pedal assembly.
`21. The system according to claim 20 wherein the top
`Surface of the floor mat has a domed shape and raised
`presence areas aligned above the non-ribbed areas on the
`bottom side of the floor mat.
`
`k
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