Auxiliary Rollers on Forks for Stationary Pallet Entry
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Solution Overview
Problem
Current materials-handling vehicles, such as pallet trucks, face challenges in successfully entering or exiting empty or lightly-loaded closed-bottom pallets due to the front load wheel striking the bottom board, causing the pallet to be pushed along the floor, which can damage the pallet and reduce operational efficiency.
Innovation Solution
The implementation of auxiliary rollers on elongated forks that apply a downward vertical force on the bottom boards of pallets, allowing the forks to enter and exit pallets without shunting, thereby maintaining the pallet's position and reducing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the front load wheel strikes the bottom board of an empty or lightly-loaded pallet, then the pallet can be pushed along the floor, but this causes damage to the pallet and reduces operational efficiency
Solution Approach 1:
The patent introduces auxiliary rollers as intermediary elements between the load wheel and the pallet bottom board. These rollers apply downward force on the bottom board without directly striking it, mediating the interaction to prevent harmful shunting while maintaining control over the pallet during entry and exit operations
Solution Approach 2:
The auxiliary rollers apply preliminary downward force on the pallet bottom board before the load wheel makes contact. This pre-applied force counteracts the tendency of the load wheel to push the pallet horizontally upon impact, preventing the harmful shunting effect before it occurs
2Reliability
If auxiliary rollers are added to apply downward force on pallet bottom boards, then pallets remain stationary during entry and exit, but this increases device complexity
Solution Approach 1:
The auxiliary rollers are integrated with the existing fork structure, merging the new function of applying downward force with the existing load-bearing and positioning functions of the fork assembly. This combination approach adds functionality while minimizing the increase in overall device complexity
Solution Approach 2:
The auxiliary rollers serve multiple functions: they apply downward force on the pallet bottom board, prevent horizontal shunting, and work in conjunction with the load wheel to control pallet movement during both entry and exit operations. This multi-functionality justifies the added components by providing multiple benefits from a single addition
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The auxiliary rollers keep unloaded or lightly-loaded pallets stationary during entry and exit, reducing damage to the pallets and enhancing operational efficiency by preventing horizontal movement and improving the success rate of pallet handling.
Implementation Method 1
The plurality of auxiliary rollers are positioned longitudinally along the length of the fork assembly such that at least one of the auxiliary rollers is on at least one bottom board of a proximal pallet
Implementation Method 2
The auxiliary rollers keep unloaded or lightly-loaded pallets stationary during entry and exit, reducing damage to the pallets by preventing horizontal movement
Data Source
Figure 1A
Figure 1B
Figure 2A~2B
AI summary
A fork assembly (100) for a forked materials-handling vehicle (10) with a chassis (102) is configured to simultaneously lift at least two inline pallets (20), each pallet (20) comprising a plurality of bottom boards (22). The fork assembly (100) comprises a plurality of elongated forks (110) and a plurality of auxiliary rollers (132/152, 134/154, 136/156, 138/158,162,164,166,168, and 190). The plurality of elongated forks (110) includes a first fork (110A or 110B) and a second fork (110B or 110A), where each fork (110) has a proximal end (112) and a distal end (114) along a longitudinal axis and the proximal end (112) of each fork (110) is attached to the chassis (102). Each fork (110) includes a load wheel (182) connected to the fork (110), and each fork (110) has a length sufficient to lift at least two pallets (20) arranged in an inline configuration. The plurality of auxiliary rollers (132/152, 134/154, 136/156, 138/158, 162, 164, 166, 168, and 190) are rotatably coupled to one or more of the plurality of forks (110), where the plurality of auxiliary rollers (132/152, 134/154, 136/156, 138/158, 162, 164, 166, 168, and 190) are positioned longitudinally along the length of the fork assembly (100) such that at least one of the auxiliary rollers (132/152,134/154,136/156,138/158,162,164,166,168, or 190) is on at least one bottom board (22) of a proximal pallet (20A) of the at least two pallets (20) when the load wheel (182) has entered the proximal pallet (20A) and contacts a bottom board (22) of the at least two pallets (20).