Dock Leveler Face Plate Pivot Anchor Design

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Solution Overview

Problem

Dock levelers face challenges such as inadequate weight distribution, high material costs, difficulties in manufacturing conical-ended springs, manual operation difficulties, unintended movement, and insufficient traction, leading to malfunctions and safety issues.

Innovation Solution

The dock leveler system includes a deck plate with a lip assembly, a face plate and pivot anchor for improved weight distribution and reduced material costs, a counterbalancing assembly with a spring and anchor plate for simplified manufacturing and uniform spring constant, a lift lever with a retainer for easier operation, and a maintenance strut for secure positioning, along with a thermosetting polyester powder coating for increased friction on traction surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If the face plate is extended lower to provide support, then the structural stability is improved, but the material costs and internal loads increase

Engineering Contradiction:

Improvestructural stabilityVSAvoidmaterial costs

Core Design Contradiction:

Stability of the object's compositionVSQuantity of substance

Solution Approach 1:

The patent introduces a vertical support member that extends downward from the face plate to provide additional support in the vertical dimension. This allows the face plate to maintain its structural stability without needing to extend horizontally further, thereby reducing material usage while maintaining load-bearing capacity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The support structure is divided into separate components: the face plate and the vertical support member. This segmentation allows each component to be optimized independently - the face plate for its primary functions and the vertical support member specifically for providing downward support, reducing overall material requirements.

Inventive Principle:

Principle #1Segmentation

2Ease of operation

If conical-ended springs are used for lifting, then the lifting assistance is improved, but the manufacturing difficulty and material costs increase

Engineering Contradiction:

Improvelifting assistanceVSAvoidmanufacturing difficulty

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The patent employs standard cylindrical compression springs instead of custom conical-ended springs. These conventional springs are cheaper to manufacture, have uniform spring constants, and are readily available, eliminating the manufacturing complexity and cost associated with conical ends while still providing effective lifting assistance.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Device complexity

If manual lift mechanisms are used, then the device complexity is reduced, but the operator burden and safety risks increase

Engineering Contradiction:

Improvemechanism simplicityVSAvoidoperator burden

Core Design Contradiction:

Device complexityVSEase of operation

Solution Approach 1:

The patent incorporates springs as counterweight elements that automatically assist in lifting the dock leveler lip. This reduces the manual effort required by operators, eliminating repetitive bending and squatting motions while maintaining mechanical simplicity. The springs provide continuous lifting assistance throughout the operation cycle.

Inventive Principle:

Principle #8Anti-weight (Counterweight)

4Ease of manufacture

If the spring has a conical portion, then the attachment facilitation is improved, but the spring constant uniformity deteriorates

Engineering Contradiction:

Improveattachment facilitationVSAvoidspring constant uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent specifies that the springs shall have a uniform spring constant throughout their length, eliminating conical portions that cause variation. Standard cylindrical compression springs with consistent diameter and wire gauge are used, ensuring homogeneous mechanical properties and predictable performance throughout the spring's service life.

Inventive Principle:

Principle #33Homogeneity

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 system enhances weight distribution, reduces material costs, simplifies manufacturing, improves operational ease, maintains secure positions, and provides reliable traction, thereby reducing malfunctions and extending the lifespan of dock leveler surfaces.

Implementation Method 1

a counterbalancing assembly comprising a spring and an anchor plate

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

a thermosetting polyester powder coating for increased friction on traction surfaces

Methodology Applied

Scientific EffectPowder coating deposition: Deposition (physical)

Implementation Method 3

for increased friction on traction surfaces

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS20240409339A1Dock Leveler With Reduced Face Plate

Publication Date: 2024.12.12 OVERHEAD DOOR CORP

AI summary

A dock leveler comprises a face plate and a pivot anchor. The face plate is disposed to abut against a wall of a dock. The pivot anchor projects laterally away from the face plate, The pivot anchor has a pivot hole configured to receive a pivot pin of the dock leveler. The pivot anchor comprises a top portion and a bottom portion. The top portion is configured to abut against the face plate and having at least one protrusion configured to couple with at least one hole in the face plate of the dock leveler. The bottom portion is disposed below the face plate and has a support surface configured to contact a wall of a dock.