forklift dimensioning systems, cube freight 400 installation

Installation & Calibration

CubeFreight 400 Lift Truck Onboard Weighing & Dimensioning System With Print Out Tickets + USB + Bar Code Scanner

Version 1.0

Integrated Visual Data Technology Inc. 3439 Whilabout Terrace, Oakville, Ontario, Canada L6L 0A7

General Installation Guide

This CubeFreight 400 system installation & calibration guide describes how to install, calibrate, test and use your lift truck on-board palletized freight check weighing and dimensioning system. Following the instructions in this guide will enable you to get your system operating quickly and easily. In the event that you require additional assistance, please contact customer support via e-mail at [email protected] or visit www.skidweigh.com or contact us at the address or contact number below:

Integrated Visual Data Technology Inc. 3439 Whilabout Terrace, Oakville, ON, Canada, L6L 0A7 Phone: 905-469-0985, Fax: 905-825-9494

SafetyAlways disconnect the vehicle battery while installing CubeFreight system or any other electronic product. Make sure sure that unit, pressure transducer and any other associated cables are securely mounted and do not impede any of the vehicle’s controls. Use care when routing the components cables. Route the cables where they will be protected. Use commonly accepted install practices for after market industrial vehicle electronic devices. The installation of the CubeFreight systems should only be performed by an acknowledged lift truck dealer technician or end user electro and hydraulic technical installer. Here are two acceptable methods of making a wire connections: * Soldering your connections (recommended) * Crimp connectors (with the use of the proper crimping tool) Regardless of the method you choose, ensure that the connection is mechanically sound and properly insulated. Use high quality electrical tape and shrink tubing where necessary.

This product is connected directly to the vehicle’s ignition switch, 12 to 55 V DC. There is no on-off switch on the unit.

Electro-Magnetic CompatibilityCE conformity to EC directive 89/336 (EMC) by application of harmonized standards: Interference stability EN 61000-6-2 and EN 61326-1 interference emit EN 61000-6-3, EN 61326-1 for the pressure transducer.

CubeFreight 400 SeriesOur policy is one of continuous improvement and the information in this document is subject to change without notice. Check that software version displayed on LCD is the one applicable for your application.


mailto:[email protected]


http://www.skidweigh.com

http://www.skidweigh.com

Overview of componentsThe standard CubeFreight 400 system consist of following components: * TFT 5.7” color touch screen digital indicator with wiring harness, mounting bracket * USB memory stick * Bar code scanner * Hydraulic pressure transducer with 3 wires cable * Pallet height assembly with distance sensor and cable * Onboard printer, thermal with paper width 57 mm (Bluetooth version) * Installation & calibration manual and operator usage instruction

Operational principalWeighing The CubeFreight 400 system check weighing & dimensioning operational principal is based on the hydraulic pressure transducer mounted in the vehicle lifting hydraulic circuit that will automatically activate the “weighing cycle / specific algorithm ” every time a skid load is lifted just above the ground. The increase in pressure is converted in an electronic signal at the sample rate of 16000 readings which is converted into a load weight reading. Pallet Height Measurement Automatic pallet height measurement system Optional Impact detection The CubeFreight models equipped with the impact detection system have the impact module mounted inside the instrument enclosure. Note: Standard Cubefreight units without impact detection module can be installed on lift truck regardless of the mounting angle or location. CubeFreight systems equipped with optional impact detection module must be installed on the lift truck in in such a way that LCD display is facing forward direction of vehicle travel, indicator mounted in vertical position having up to +/- 15 degree angle that is allowed for proper operation.

Pressure transducer installationThe pressure transducer must be installed in the lifting hydraulic line between the lift control valve and lift cylinder(s). Mount a T-piece in lifting hydraulic line. In some cases you can install the pressure transducer in the flow divider, drilling and tapping for 1/4”-18 NPT male in spare plug or in the body of the flow divider. Also, you can drill and tap on any “larger elbow” that might be available in the hydraulic lifting circuit.


Pressure transducer installation precautions Before installation of the pressure transducer the hydraulic lift circuit must be pressure free. There are two ways to do that: 1. Place the forks on the ground in their lowest position and make the hydraulic system pressure free by tilting the mast forward. The chain(s) should be slack. 2. Lift the forks and position them on the top of a supporting fixture. Start lowering the lifting cylinder into its lowest position. Be sure that chain(s) are slack. Make sure that that installed pressure transducer will not touch any moving parts or assembly of the vehicle while in normal operation. Pressure transducer has 1/4”-18 NPT male thread. Use thread seal to ensure tight fit.

Selecting the mounting location for digital indicatorUse the mounting bracket to fasten digital indicator on the vehicle dashboard, side railing or preferably on the top of the operator guard enclosure, right hand side.

There are many examples of mounting locations that will depend on the vehicle model. However, additional mounting items such as a flat brackets may be needed to help secure the unit to upper right corner of the guard or side railing.

Compact size All of the CubeFreight systems are compact size, housing dimension of only 178 mm x 144 mm x 48 mm.

Electrical ConnectionsAll CubeFreight systems operate from 12 to 55 V DC. .

- Orange Wire (+) Ignition switch “on position” - Brown Wire (-) Battery negative - Red Wire, connect to RED wire of the pressure transducer cable - Black Wire, connect to BLACK wire of the pressure transducer cable - White Wire, connect to WHITE wire of the pressure transducer cable


Pressure transducer cable White Wire, signal 0 to 2,5 V Black Wire, signal negative Red Wire, power supply to pressure transducer + 11 V DC

Pallet Height Sensor Telescopic pole assembly, pallet height distance sensor with DB9 connector cable

Electrical power short circuit protection - All of the CubeFreight systems are internally short circuit protected with resettable fuse. There is no need to install external inline fuse in orange wire connected to the ignition switch.- Automotive 60 V load dump protection. Reversal power supply protection.

“Quick test to determine if electrical connections are done right” After you have connected electrical power and pressure transducer cable you can check the system operation. - Turn ignition switch On.

- Tap on “Home” icon and you will get into the main system page screen with 6 icons. Tap on “Clock & More” icon.

- Tap on “Pressure Transducer Test” icon. The LCD screen will show the pressure readings in digital format. If you start to lift and loweing the forks and sensor readout value shown on LCD display should change up and down if the pressure transducer is connected properly. Tap on “Back” icon to get back to the main screen page. If the above test is valid than the system and pressure transducer electrical connections are done right. The next procedure will be to calibrate the CubeFreight weighing & dimensioning functions.

Lift truck equipped with hydraulic accumulator If the standard CubeFreight system is installed on the lift trucks equipped with hydraulic accumulators, please contact us to provide you with instruction to enter specific software algorithm to obtain load weight accuracy within +/- 0.1 to 1% of vehicle maximum lifting capacity.


Weighing function calibration procedure The CubeFreight calibration is automatic and is done by lifting empty and loaded forks (or any other attachment such as paper clamp) just above the ground. MAKE SURE THAT YOU HAVE A KNOWN LOAD WEIGHT AND KEEP IT NEARBY TO COMPLETE THE CALIBRATION. For the best results use at least minimum calibration load test weight of 30 to 50% of maximum lifting capacity of the lift truck. Use customer floor scale or find a known skid load weight within the operational facility. Important: If you want the system to show load weight in pounds, use the known load weight in pounds and enter that value accordingly. The same would apply if you want the system to show load weight in

kilograms.

CubeFreight System Set Up & Calibration

DATE / TIME - Tap on “Home” icon and than tap on the “Clock & More” icon. - Tap on “Set Clock” icon.

- Tap on the “Set” icon and use “arrow up” and “arrow down” input to change time and date if required. - When proper clock / time set up is done, tap on the “Home” icon to save the values.


WEIGHING FUNCTION CALIBRATION

CubeFreight weighing function calibration starting point Lower the empty forks to the ground. There should be no hydraulic pressure in lift hydraulic circuit. Turn ignition switch to on position (electric lift trucks) and start the engine on combustion powered lift trucks.

LCD display will show standard weighing mode.

- Tap on “Home” icon. - With LCD showing all of the six icons, tap on the “Calibrate” icon. - The LCD display will show two icons, “Weighing” and “Height” icons. - Tap on the “Weighing” icon. - The LCD display will show picture of the empty forklift and the message “Lift Empty Forks”.

Calibration of empty forks System is ready for automatic zeroing of the scale function. With empty forks on the ground initiate the lift and lift the empty forks just above the ground. ( About 2”)

Activate lift control valve “quickly” lift empty forks. Do not lift empty forks slowly ! The % of the calibration cycle will be shown on LCD display. Wait few seconds until display shows 100%. The LCD display will indicate to lower empty forks. Calibration for empty forks is done. The LCD display will automatically go to the next screen where you have to enter a known calibration load weight.


Example:” Known load weight is 1528”. Note: The known load weight could be in pounds or kilograms. Press Enter key when your known calibration load weight is inputed into the system.

Calibration of loaded forks with known load weight With loaded forks on the ground lift forks just above the ground. Activate lift control valve “quickly” to lift loaded forks. Do not lift loaded forks slowly ! Wait few seconds until display shows 100%. The LCD display will indicate to lower empty forks.

Calibration of loaded forks with known load weight is done.


PALLET HEIGHT MEASUREMENT

The pallet height measurement is automatically taken without operator input during the normal operation. Please consult the operational instruction for standard weighing and dimensioning.. Note: The mounting and calibration of the pallet height sensor assembly is easy. Please read below general considiration that might apply for your vehicle mast configuration. The calibration is fully automatic consisting of taking only one measurement of the distance from the pallet height sensor to the ground floor.

Pallet Height Sensor Mounting Location The pallet height sensor assembly is mounted on the vehicle mast. The base of the assembly has two magnets for easy installation on the top of the vehicle mast or on the side of the mast. There is no need for additional mechanical work, brackets, drilling, etc. or mounting hardware in order to install the pallet height measurement assembly. Telescopic adjustable pole is the convenient method to adjust and bring the pallet height sensor into the desirable measurement area on the vehicle. The majority of the installation for the CubeFreight digital indicator is done on right side of the dashboard area. Pallet height sensor assembly mounting location is also done on the right mast looking forward direction of the vehicle travel.

Note: The CubeFreight pallet height sensor operational range is from 12” to 144”. The end user application and operational environment will determine the maximum mounting height for the sensor. Very often the sensor can not be more than the height of the standard lift truck mast height. In typical LTL freight operational environment where lift truck are moving in and out of the trailers the maximum mounting height of the sensor is limited to the inside dimensions of the trailer, less few inches. Also the mounting height will be reduced if trailers are equipped with pull down doors or / and loading docks that are equipped with environmental protection curtain which will reduce the maximum sensor mounting height for another several inches.


The end user is responsible to determine the pallet height sensor to the optimum height location on the lift truck in order for the sensor not to get damaged. As of example in LTL freight forwarding industry about 78 % of palletized freight is not higher than 72”. The best way is to keep the pallet height sensor mounting location at the same height location as the standard vehicle mast height.

Pallet Height Sensor Positioning The CubeFreight pallet height sensor is high resolution ultrasonic range finder with target size compensation developed specifically for the palletized height measurements system mounted on lift truck vehicles. It’s important that sensor is mounted perpendicular to the target ( typical pallet load) within +/- 5 degree for the best results of the distance accuracy readings withn one inch).

Telescopic Tube & Sensor Adjustment The CubeFreight pallet height sensor assembly can be adjusted to accommodate all kinds of vehicles equipped with standard mast and short mast used in many LTL loading dock operations. In the case of the standard mast the telescopic tube assembly can be attached on the top or side of the mast. Make sure that telescopic tube is extended for at least 12” to 18” from the mast toward the area in front of the carriage. The pallet height sensor must be positioned perpendicular to the target, in our case towards typical pallet load. The assembly allows the adjustment for both, length of the telescopic pole and the sensor positioning 360 degree.


Caution Lifting or handling loads higher than pallet height sensor mounting location The CubeFreight pallet height distance measurement system is designed to measure the palletized load to height up to 144”. The material handling operations use all kinds of lift trucks with different mast height configurations. The majority of the operational facilities are equipped with vehicles having standard mast height of 87”. The LTL operations use the the short mast configuration having the mast height of about 50”. As of example if the mounting location of the pallet height sensor on the top of the mast with 87” positioned beyond the carriage and operator is picking up double stacked loads of 48” (2 times 48” = 96”) would result in the sensor being “pushed” or damage. The same would apply if the forks are being lifted to the next stage. Solution A: The operator must be aware of this “operational conditions” and get off the vehicle and re-adjust telescopic pole bringing the sensor behind the cariage or load rest and the pallet height sensor will be protected! At any time the telescopic pole can be re-adjusted and put back into the measurement area without any need to re-calibrate the system. Solution B: Installation of the linear actuator with operator activated switch that will move pallet height sensor in and out of the measurement area in front of the mast. This would eliminate operator getting off the vehicle to re-adjust the sensor positioning, but is not a foolproof. If the operator forgets to activate the switch to retract the sensor the damage might occure as well. For additional cost of the linear actuator, please contact [email protected].

Pallet Height Sensor Calibration - Connect pallet height sensor DB9 cable to the DB9 cable from the Cubefreight system. - Secure the cable with plastic ties and make a loop from the mast to the body of the vehicle. - Make sure that sensor is beyond the carriage / load rest assembly and in the area for proper pallet height readings. - Sensor must be perpendicular to the ground floor. - Move the fork towards to opposite side in order to calibrate the distance sensor against the ground floor only.

- Tap on “Home” icon. - Tap on “Calibrate” icon. - Tap on “Height” icon. - The LCD screen will show distance value in inches - Tap on OK icon. (You can use a measurement tape to confirm the shown distance value) - Calibration for pallet height measurement is done - LCD screen will go back to the main six icons page




User’s Manual The CubeFreight system has two “Weighing modes” to accommodate the end user’s operational needs. - The standard weighing mode - The weighing and dimensioning mode

User’s Manual (Standard Weighing Mode) Tap on “Operate” icon

User’s Manual (Weighing and Dimensioning Mode) Tap on “Cube Weight” icon


Standard Weighing Mode * Standard weighing * Parts count by weight

* TARE input by re-weigh or keypad input

Lift Truck / Operator Cubefreight LCD Display

Remarks

- Tap on “Home” icon - Tap on “Operate” icon

Note: - To use weighing function only of the CubeFreight system you must tap on the “Operate” icon.

Load weighing starting point

- Insert the forks into the load, lower the forks to the ground.

Proper weighing procedure

- Lift the load weight just above the ground - LCD will show “Please Wait” with % of the weighing cycle status in progress

Printing individual load weight

- After few seconds LCD will show “Done” with lifted load weight value shown on LCD screen - Choose Add to accumulate more load weights or tap on the “Send” icon to get a single printout ticket and USB recording.

- To initiate another load weight repeat the above procedure

- Choose Add to accumulate more load weights and when finished tap the “Send” icon to get a printout ticket of all individual loads weights and total weight and USB recording.



Remarks

Optional Waybill ID# input for load weights

- CubeFreight with optional Waybill ID# function, if you tap on “Send” icon the LCD screen will prompt you to enter a valid Waybill number. - Press Enter key

Optional accumulative load weight total

- CubeFreight with optional accumulative load weight total, tap on “Add” icon to keep totalizing the load weights.

Tare Input by keypad

- Tap on “Home” icon - Tap on Clock & More icon. - Tap on “Tare Input by Keypad” - Input your Tare value and press Enter key - TR sign will be shown on LCD display

How to re-set Tare input set by keypad

- Press TR sign to cancel current Tare - TR sign will be not shown on LCD display * The last Tare input will be shown in “Tare Value Table”.

How to set Tare value by reweigh

- Tap on “Home” icon - Tap on Clock & More icon. - Tap on “Tare input by Reweigh” - “Lift Empty Forks” with additional item (container, box,etc.) to recalibrate for new Tare - TR sign will be shown on LCD display



Remarks

How to re-set Tare input by reweigh

- Tap on TR sign to cancel current Tare input by reweigh

- TR sign will be not shown on LCD display

How to set Parts count by Weight

- Tap on “Home” icon - Tap mo Clock & More icon. - Tap “Parts count by weight”

Parts count by Weight

- In “Part Weight” table input the weight of individual part weight. Use decimal point if required.

- Tap “Next” to confirm the part weight

Parts count by Weight

- Lift the load weight - LCD display will show load weight and Part count - You can add other loads and keep track of the total part counts

To change or re-set Parts count by weight function

- Tap on “Home” icon - Tap on “Clock & More” icon. - Tap on “Parts count by weight” - Change value of the current part weight in the table or re-set by inputing “0 “ value and tap on “Next”.


Weighing and Dimensioning ModeWhen operating in the “CUBE WEIGHT” function of thr system you must follow through the automatic sequence to obtaine load weight and the dimensioning of the palletized load. As long the palletized load height is within 12” and your maximum detection height the pallet height measurement is automatic without operator input. If the pallet height is out of the range or sensor is faulty the systems goes automatically into the ‘Manual input mode”. Operator will have to enter all 3 pallet size values manually via the keypad on LCD display. System will be operational, DIM calculation will be performed and print out tickets will be available.

All “Weighing & Dimensioning Measurements” cycles requires the Waybill ID# as a starting point

Lift Truck / OperatorLift Truck / Operator Cubefreight LCD Display

Remarks

Starting Point - Tap on “Home” icon - Tap on “ Cube Weight” icon

Starting Point - Tap on “Home” icon - Tap on “ Cube Weight” icon

Note: - To use weighing and dimensioning function of the CubeFreight system you must tap on “CUBE WEIGHT” icon. - Pick up the palletized load

- Enter a valid Waybill ID# via the LCD keypad or use the built in bar code scanner

- Enter a valid Waybill ID# via the LCD keypad or use the built in bar code scanner

- Enter valid Waybill ID# and tap on Enter icon

Note: Every new Weighing & DIM Dimensioning session starts with the input for the Probill ID# or Waybill ID#

The LCD display will show “Begin” Pick up the first palletized load and lowered to the

ground to initiate measurement cycle - Tap on the “Begin”

Example: Single liftExample: Single lift

- LCD display will show Pallet 1 - If pallet load is not on the ground the LCD message “Lower Forks” will be shown. - Lower the forks to the ground.



Remarks

With pallet lowered to the ground the pallet height

measurement will be done automatically.

At this point you have to make decision. 1. Is this a right pallet ? 2. Is this a different pallet ? 3. Do I need to enter manually all 3 dimensions ?

With pallet lowered to the ground the pallet height

measurement will be done automatically.

At this point you have to make decision. 1. Is this a right pallet ? 2. Is this a different pallet ? 3. Do I need to enter manually all 3 dimensions ?

- The pallet height measurement will be automatically taken and will be shown on the LCD display once the pallet load is lowered to the ground. - Current default pallet value ( as of example 48” x 40”) will be shown on LCD display. - Lift Load prompt will be shown on LCD display.

BEFORE YOU LIFT THE LOAD Make a choice! A - If this is the right pallet size, lift the load just above the ground to get a load weight. - If this load measurement is the only load under that Waybill ID# tap on the “Send” icon. - DIM session will be completed and information will be send to the printer and to the USB memory stick. B - If the current default pallet size is the wrong size than you can change it. - Tap on “Pallet” icon to input different pallet size from the “Select Pallet Size” table. You can also enter manually all 3 dimensions if that is required. - When the right pallet is selected from the table tap on the “Next” icon. - Lift the loaded forks to get a load weight. - If this is the only load under that Waybill ID# tap the “Send” icon. - Session will be completed and information is send to the printer nand USB memory stick.



Remarks

Example: More thant the single lift

There are more than one lifts required under that particular

Waybill ID#

Example: More thant the single lift

There are more than one lifts required under that particular

Waybill ID#

- After you have complited the first measurement cycle ( Pallet height and load weight obtained) the LCD will display weight, pallet height and indicate as the Pallet 1. - Pick up net next palletized load, you must always lowered to the ground and than tap on the “Next”. - Lift the second pallet just above the ground. - LCD display will show “Done” above the current load weight, in addition to the weight, pallet height, total accumulated weight, pallet height and indicate as the Pallet 2. Note: You can keep doing this as long is required to complite that particular Waybill ID#. Important: Tap on the “Next” when your next palletized load is on the ground and is ready for the measurement. - With your last palletized load measurement tap on “Send”. This will close the session and all information under that particular waybill ID# will be printed out. Information will be also send to the USB memory stick. Oversized freight - For all oversized freight choose the “Manual” input from the “Select Pallet Size” table. Enter all palletized dimensions (or larger pieces) in inches. - You must input the load weight manualy (from customer Waybill) as well to close the current measurement item.

NEW STARTING POINT - Enter a valid Waybill ID# via the LCD keypad or use the built in bar code scanner

NEW STARTING POINT - Enter a valid Waybill ID# via the LCD keypad or use the built in bar code scanner

- Enter valid Waybill ID# and tap on Enter icon

Note: Every new Weighing & DIM Dimensioning session starts with the input for the Probill ID# or Waybill ID#


forklift dimensioning systems, cube freight 400 installation

Technology

hydraulic pressure transducer

hydraulic system pressure

hydraulic lift circuit

system check

impact detection system

cubefreight systems

hydraulic circuit

cubefreight models