Method for manufacturing lightweight plastic pallet

Abstract

This invention discloses a method for manufacturing a lightweight plastic pallet, comprising: performing structural simulation analysis on a three-dimensional model of the original plastic pallet using structural simulation analysis software to obtain a first stress distribution simulation result of the original plastic pallet; selecting at least one local area with a stress parameter lower than a preset stress threshold as a material reduction area based on the first stress distribution simulation result; performing lightweight design modifications on the material reduction area to generate a corresponding lightweight pallet three-dimensional model; performing structural simulation analysis on the lightweight pallet three-dimensional model using structural simulation analysis software to obtain a second stress distribution simulation result, and comparing the second stress distribution simulation result with the first stress distribution simulation result to confirm that the variation in stress or deformation does not exceed a preset allowable range.

Claims

1. A method for manufacturing a lightweight plastic pallet, comprising: a model input step, comprising: inputting a three-dimensional model of an original plastic pallet into structural simulation analysis software running in a computer unit; a simulation analysis step, comprising: using the structural simulation analysis software to perform structural simulation analysis on the three-dimensional model, thereby obtaining a first stress distribution simulation result of the original plastic pallet; a region selection step, comprising: selecting at least one local region with a stress parameter lower than a preset stress threshold as a reduction region based on the first stress distribution simulation result; a lightweight design step, comprising: performing lightweight design modifications on the reduction region to generate a corresponding lightweight pallet three-dimensional model; wherein the design rules in the lightweight design step include reducing the thickness of the ribs in the reduction region, wherein the thickness reduction range is 30% to 60% of the original thickness of the ribs, and the thickness reduction includes only reducing the thickness of the middle section of the ribs, retaining the original thickness at the joints between the two ends of the ribs and the main structure, and the middle section and the two ends are connected by a chamfer transition. A simulation verification step includes: using the structural simulation analysis software to perform structural simulation analysis on the three-dimensional model of the lightweight pallet to obtain a second stress distribution simulation result, and comparing the second stress distribution simulation result with the first stress distribution simulation result to confirm that the variation in stress or deformation does not exceed a preset allowable range; wherein, In the simulation verification step, the preset allowable range is that the difference between the maximum stress value of the second stress distribution simulation result and the maximum stress value of the first stress distribution simulation result does not exceed ±15% or the difference in maximum deformation does not exceed ±20%; and an injection molding step includes: manufacturing a lightweight plastic pallet by injection molding based on the confirmed lightweight pallet three-dimensional model.

2. The manufacturing method as described in claim 1, wherein the structural simulation analysis software is finite element analysis software.

3. The manufacturing method as claimed in claim 1, wherein the simulation analysis step includes applying a predetermined load condition and boundary condition to the three-dimensional model and performing a structural simulation analysis.

4. The manufacturing method as claimed in claim 3, wherein the predetermined load condition is provided on the upper surface of the three-dimensional model of the original plastic pallet, applying a concentrated load vertically downward and with a force range between 1,800 and 2,200 Newtons.

5. The manufacturing method as claimed in claim 1, wherein in the region selection step, the preset stress threshold is set to 30% to 80% of the maximum stress value or maximum deformation in the first stress distribution simulation result.

6. The manufacturing method as claimed in claim 1, wherein in the region selection step, the preset stress threshold is set to 40% to 70% of the maximum stress value or maximum deformation in the first stress distribution simulation result.

7. The manufacturing method as claimed in claim 1, wherein the design rules in the lightweight design step further include adjusting the rib configuration pattern by increasing the number of ribs and correspondingly reducing the thickness of a single rib to reduce the pallet volume.

8. The manufacturing method as described in claim 1, wherein if the second stress distribution simulation result does not exceed the preset allowable range, and the volume reduction of the lightweight pallet model has not reached a maximum volume reduction percentage, the manufacturing method returns to the lightweight design step for redesign and resimulation.

9. The manufacturing method as described in claim 1, wherein in the simulation verification step, when the simulation result of the second stress distribution falls within the preset allowable range and the volume reduction percentage has reached the maximum volume reduction percentage, the three-dimensional model of the lightweight pallet is defined as an optimal model.

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