Dock Leveler Deck Beam and Adjustable Leg Bracket
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Solution Overview
Problem
Current dock leveler designs face challenges such as complex and time-consuming installation processes due to the need for shimming, lack of adjustability for non-standard pit dimensions, and instability, leading to increased maintenance and costs over their lifetime.
Innovation Solution
The dock leveler design incorporates a bridge assembly with a pivotally movable lip, an adjustable leg bracket assembly featuring a threaded adjustment shaft, and a lip keeper system that allows for adjustment relative to the beam, enhancing stability and simplifying installation by reducing the number of parts and eliminating the need for shimming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional dock leveler designs are used, then the dock leveler can be installed, but the installation process becomes complex and time-consuming due to the need for shimming multiple parts
Solution Approach 1:
The patent removes the shim component from the traditional dock leveler assembly and replaces it with an adjustable leg bracket mechanism. The leg bracket assembly includes a threaded adjustment shaft that allows height adjustment without requiring shims, thereby eliminating the complex shimming process and reducing installation time while maintaining the necessary leveling function.
Solution Approach 2:
The patent introduces dynamic adjustability to the leg bracket assembly through the threaded adjustment shaft mechanism. This allows the dock leveler to adapt to different pit depths and dock heights during installation and operation, replacing the static shim-based leveling approach with a dynamic adjustment system that simplifies the installation process.
2Adaptability or versatility
If traditional dock leveler designs are used, then the dock leveler can be installed in standard pits, but it cannot be easily adjusted to accommodate non-standard pit dimensions or varying dock heights
Solution Approach 1:
The adjustable leg bracket assembly serves multiple functions: it provides structural support, enables height adjustment, and accommodates varying pit dimensions. The threaded adjustment shaft mechanism allows a single component to perform what traditionally required multiple specialized parts (shims, brackets, and adjustment mechanisms), thereby increasing adaptability while reducing overall device complexity.
3Reliability
If traditional dock leveler designs are used, then the dock leveler can operate, but parts lack optimal stability and longevity leading to increased maintenance costs
Solution Approach 1:
The patent incorporates a preliminary adjustment mechanism during installation that allows the leg bracket assembly to be pre-leveled and stabilized. The threaded adjustment shaft can be used to achieve optimal positioning before operation begins, and the design includes features to maintain this positioning, thereby improving stability and reducing the need for maintenance adjustments throughout the dock leveler's service life.
Data Source
AI summary
A dock leveler that fits within a loading dock. In some embodiments, the dock leveler may include a leg bracket assembly couplable to a back wall of the dock and a deck. The leg bracket assembly may include a deck hinge shaft. The deck may include a deck platform having a back end and a front end and a beam coupled to a bottom surface of the deck platform. The deck may include a C-shaped profile, a first end coupled to the bottom surface of the deck platform proximate to the back end, and a second end coupled to the bottom surface of the deck platform proximate to the front end. The first end of the beam may include an extension having a cutout shaped to fit around the deck hinge shaft.