Pre-assembled Dock Door Spring Shaft Assembly for Fast Installation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current dock door installation methods are time-consuming and costly, requiring multiple trips and many parts, which hinders efficient installation in the rapidly growing warehouse and shipping industry.
Innovation Solution
A dock door assembly and kit featuring pre-assembled components such as vertical tracks, spring shaft assemblies, and cable systems, which include torsion springs and counterbalance mechanisms, allowing for faster and more cost-effective installation by minimizing parts and installation time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional dock door installation methods are used, then the door can be installed with multiple parts and trips, but the installation time and cost increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-assembling the spring shaft assembly with cable drums and torsion springs before delivery to the installation site. This pre-assembly eliminates the need for installers to assemble these complex components on-site, directly reducing installation time while maintaining the ability to complete the door installation with minimal trips.
Solution Approach 2:
The patent merges multiple components into integrated assemblies. The spring shaft assembly combines the shaft, cable drums, and torsion springs into a single pre-assembled unit. The headplate integrates mounting holes for both the vertical track and spring shaft assembly, reducing the number of separate parts and simplifying the installation process.
2Ease of manufacture
If traditional installation methods with many parts are used, then the door can be assembled, but the number of parts and trips required increases
Solution Approach 1:
The patent segments the dock door system into distinct modular assemblies: the spring shaft assembly (with shaft, drums, and springs), the headplate assembly, the cable assembly, and the door panel assembly. This segmentation allows each module to be pre-assembled and tested independently, then installed as complete units, reducing the complexity of on-site assembly while maintaining ease of installation.
Solution Approach 2:
The patent applies preliminary action by pre-assembling the spring shaft assembly with cable drums and torsion springs before delivery to the installation site. This pre-assembly eliminates the need for installers to assemble these complex components on-site, directly reducing installation time while maintaining the ability to complete the door installation with minimal trips.
3Loss of time
If minimal parts and trips are used for installation, then installation time is reduced, but the door must still withstand wind loads and operational stresses
Solution Approach 1:
The patent applies the counterweight principle through the torsion spring assembly that counterbalances the weight of the door panels. This mechanical counterbalance system ensures the door can be easily controlled during operation and remains stable under various loading conditions, including wind loads, without requiring additional support structures that would complicate installation.
Solution Approach 2:
The patent applies preliminary action by pre-assembling the spring shaft assembly with cable drums and torsion springs before delivery to the installation site. This pre-assembly eliminates the need for installers to assemble these complex components on-site, directly reducing installation time while maintaining the ability to complete the door installation with minimal trips.
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 dock door assembly and kit enable installation in approximately 30 minutes, significantly reducing time and labor costs compared to traditional methods, while ensuring secure and wind-resistant operation.
Implementation Method 1
at least one counterbalance torsion spring extending along the torsion shaft
Implementation Method 2
a pair of cable drums with each cable drum located near an end of the torsion shaft
Data Source
AI summary
A dock door assembly and a dock door assembly kit are provided for use in a dock door opening for installation in a warehouse. The dock door assembly comprises a pair of vertical tracks, with each vertical track configured to be attached to a wall along opposing lateral sides of the dock door opening. The dock door assembly also comprises a multiple, horizontal section door characterized by a vertical height when closed and mounted on the pair of vertical tracks. The dock door assembly further comprises a spring shaft assembly and a pair of headplates with each headplate having a U-shaped opening to receive each end of a torsion shaft. Further, the dock door assembly may comprise a pair of door cables and a pair of corner cable attachments connecting each door cable to the spring shaft assembly.