Adaptor Pallet Lever-Operated Locking Mechanism
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Solution Overview
Problem
Current adaptor pallets are cumbersome, inefficient, and ergonomically poor due to complex locking mechanisms that hinder effortless loading and storage, often leading to operator discomfort and damage when stacking empty pallets.
Innovation Solution
A new locking mechanism with fully independent, lever-operated locking members that can be deactivated without releasing the dolly, allowing for hands-free operation and enabling safe stacking by allowing the lever to remain horizontal, reducing the risk of damage from forklifts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional locking mechanisms are used to secure dollies on adaptor pallets, then the dollies are prevented from moving during transport, but the locking mechanisms become cumbersome and difficult to operate
Solution Approach 1:
The locking mechanism is designed to be self-activating through spring-loaded locking members that automatically engage with the dolly body when the dolly is placed on the pallet. The operator simply needs to position the dolly, and the springs automatically secure it, eliminating the need for manual manipulation of complex locking components.
Solution Approach 2:
The locking system is divided into multiple independent locking members, each capable of securing individual dollies separately. This segmentation allows for independent operation of each locking mechanism, simplifying the overall operation while maintaining secure attachment of multiple dollies to the pallet.
2Reliability
If locking members are activated to secure dollies, then dollies are firmly held in position, but the mechanism becomes difficult to deactivate without releasing the dolly
Solution Approach 1:
The locking members are designed with spring-loaded activation where the springs automatically engage the locking members with the dolly body. To deactivate, the operator simply applies downward pressure on the lever, which overrides the spring force and releases the locking members, allowing easy deactivation without needing to manually manipulate complex mechanisms.
3Reliability
If conventional locking mechanisms are used, then dollies are secured during transport, but the mechanisms are difficult to negotiate while supporting heavy dollies
Solution Approach 1:
The spring-loaded locking members automatically engage with the dolly body without requiring the operator to manually manipulate locking components while supporting the heavy dolly. The operator only needs to position the dolly on the pallet, and the springs automatically secure it, eliminating physical strain during the securing process.
4Reliability
If locking members are activated in conventional pallets, then dollies are secured, but empty pallets cannot be safely stacked due to potential damage from forklift forks
Solution Approach 1:
Instead of having the locking members extend upward to engage dollies (which would protrude and be vulnerable to forklift damage), the mechanism is inverted so that the locking members engage from below or at the same level as the pallet surface. The lever operates horizontally rather than vertically, keeping all components flush with the pallet surface and eliminating vulnerability to forklift fork damage during stacking.
5Reliability
If conventional locking mechanisms are used, then dollies are secured to pallets, but the loading process requires releasing the dolly from previous locking positions
Solution Approach 1:
Each locking member operates independently and can be activated or deactivated separately. When loading multiple dollies, the operator can activate locking members sequentially for each dolly without needing to deactivate previous ones, as each locking member is isolated and functions autonomously. This eliminates the time-consuming process of releasing and re-engaging locking mechanisms for each dolly.
Data Source
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AI summary
An adaptor pallet (10) which comprises at least one load bearing deck (12) to receive the wheels (22) of a dolly (20), the load bearing decks (12) that are separated by at least one lifting point (18) to receive the lifting forks of a forklift as well as at least one locking member (16) to engage with the dolly (20) the locking member (16) being adapted to be manipulated with activation means. The activation means comprises at least a lever (14) and it is adapted to deactivate said locking member (16) when it is moved in its first degree of freedom. Also the activation means is adapted to activate said locking member (16) when it is moved in its second degree of freedom. A method of handling cargo.