Dock Leveler Deck Hinge Layout for Frameless Pit Installation
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Solution Overview
Problem
Current dock leveler designs are cumbersome to install, pose safety risks during maintenance, and create weak points prone to failure due to heavy loads, with issues like trapping debris and requiring extensive cleaning.
Innovation Solution
A dock leveler design featuring a frameless structure with a leg bracket, deck hinge, and lip hinge that minimizes parts, enhances installation efficiency, and reduces debris trapping, while providing stable support through a C-shaped bracket and shaft configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a large steel frame is used to provide stability and connection points, then structural stability is improved, but installation becomes cumbersome and dangerous, and maintenance requires crawling under the heavy deck
Solution Approach 1:
The patent removes the large steel frame entirely from the dock leveler design. Instead of using a traditional frame structure, the invention employs a deck hinge mechanism where the deck is hinged to the leg bracket, allowing the deck to pivot and float without requiring a cumbersome steel frame for support and connection.
2Stability of the object's composition
If a large steel frame is used, then structural stability is improved, but maintenance complexity increases due to the need to crawl under the deck
Solution Approach 1:
By removing the steel frame completely and replacing it with a deck hinge system, the patent eliminates the need to crawl under the deck for maintenance. The hinge mechanism allows the deck to be accessed from above, significantly improving maintenance ease while preserving structural stability through the hinged connection.
3Stability of the object's composition
If a steel frame structure is used, then structural stability is improved, but debris trapping increases requiring extensive cleaning
Solution Approach 1:
The patent eliminates the steel frame structure that creates spaces and crevices for debris accumulation. The frameless design with the deck hinged to the leg bracket creates a smoother, more open structure that prevents garbage and free-floating items from getting trapped, reducing cleaning requirements.
4Stability of the object's composition
If traditional installation methods are used, then structural stability is improved, but connection reliability decreases due to weak points prone to break
Solution Approach 1:
By removing the steel frame and its associated connection points, the patent eliminates the weak connection points that are prone to breaking under heavy loads. The deck hinge mechanism provides a more reliable connection between the deck and leg bracket, improving connection reliability while maintaining structural stability.
Data Source
AI summary
A dock leveler with a deck hinge shaped to fit in the pit of a loading dock. The dock leveler may have a rear leg bracket including a plurality of legs couplable to a bottom surface and a rear wall of the pit. The leg bracket may be positioned directly adjacent the rear wall and may include a plurality of brackets having an upwardly facing opening configured to receive a cylindrical shaft. The dock leveler may also comprise a deck that may have a rear portion shaped to fit over the cylindrical shaft and located adjacent the rear wall. The cylindrical shaft may be sized to fit within the plurality of brackets such that the rear portion of the deck and the shaft may be disposed directly above the legs of the leg bracket.