Automated Pallet Assembly Using Pre-Shaped Segmented Components
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Solution Overview
Problem
Existing methods for fabricating paperboard pallets are inefficient and lack automation, making them unsuitable for rapid and cost-effective production, especially under extreme load conditions during transport on open racks.
Innovation Solution
A method for mechanically assembling pallets from pre-shaped three parts - a bottom part, an upper part, and an envelope - using corrugated cardboard or polypropylene corrugated cardboard, with specific notch and fold designs that allow for automated production and enhanced structural rigidity, preventing U-sag and ensuring stability on open racks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembling, folding and sticking methods are used for paperboard pallets, then the fabrication process is simple and flexible, but the production speed is slow and cost efficiency is poor
Solution Approach 1:
The pallet is divided into multiple pre-cut components (bottom part, upper part, envelope, supporting feet, channels) that can be independently manufactured and then automatically assembled. This segmentation enables each component to be optimized for automated cutting and assembly operations, significantly increasing production speed while maintaining manufacturing simplicity through standardized component designs.
Solution Approach 2:
Components are pre-cut with notches, folds, and adhesive application areas prepared in advance before assembly. The supporting feet, channels, and other elements are pre-formed with precise geometries that enable automatic alignment and joining. This preliminary preparation of components allows the assembly process to proceed rapidly through automated operations without requiring complex real-time adjustments.
2Strength
If traditional pallet designs are used, then the structure is simple to manufacture, but the load capacity and stability under extreme conditions are insufficient
Solution Approach 1:
The pallet utilizes corrugated cardboard or polypropylene corrugated cardboard materials that combine multiple layers with different orientations to achieve high strength-to-weight ratios. The corrugated structure provides inherent rigidity and load-bearing capacity while maintaining relatively simple manufacturing processes for cutting and assembly.
Solution Approach 2:
The envelope and supporting feet incorporate curved surfaces and folded geometries that distribute loads more effectively across the structure. The notches and folds create three-dimensional forms that enhance structural rigidity and resistance to deformation under extreme loading conditions, while still being manufacturable through standard cutting and folding operations.
3Stability of the object's composition
If racks are used on open racks without proper design, then the pallet is easy to handle, but U-sag occurs and stability is compromised
Solution Approach 1:
The pallet design incorporates specific structural features at critical locations: reinforced channels for fork truck entry, strategically positioned supporting feet, and enhanced envelope sections at load-bearing areas. These localized reinforcements prevent U-sag and improve rack stability without adding complexity to the overall handling operations. The bottom and upper parts are designed with specific geometries that engage with rack structures to prevent sagging while maintaining ease of forklift insertion and removal.
Data Source
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AI summary
A pallet composed of three basic parts, a bottom part (la), an upper part (2a) and an envelope (3a), wherein said three parts are pre-shaped and can be mechanically assembled in an automated method.