Dock Leveler Lip Keeper Adjustment Mechanism

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Solution Overview

Problem

Current dock leveler designs face challenges with installation complexity, stability issues, and maintenance costs due to the need for shimming and lack of adjustability to accommodate varying pit dimensions, leading to suboptimal performance and longevity.

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

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional dock leveler designs are used, then the basic function of bridging the gap is achieved, but installation complexity increases and stability is compromised due to the need for shimming

Engineering Contradiction:

Improveinstallation efficiencyVSAvoidnumber of parts

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent removes the shim component from the traditional dock leveler assembly and replaces it with an adjustable leg bracket mechanism. This extraction eliminates the need for shimming while maintaining the ability to accommodate pit dimension variations, directly reducing installation complexity and the number of parts required.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The leg bracket assembly is designed with adjustable components that can be dynamically positioned to accommodate different pit dimensions. The bracket includes adjustment mechanisms that allow it to adapt to varying conditions without requiring multiple fixed parts or shimming procedures, improving ease of installation while maintaining stability.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If fixed position components are used, then manufacturing is simplified, but adaptability to varying pit dimensions is reduced

Engineering Contradiction:

Improveadjustability to pit dimensionsVSAvoidnumber of adjustable parts

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The adjustable leg bracket assembly serves multiple functions: it provides structural support, accommodates varying pit dimensions, and eliminates the need for shimming. This multi-functional design increases adaptability to different installation conditions while avoiding the complexity of having separate adjustment mechanisms for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The bracket assembly incorporates dynamic adjustment capabilities that allow it to adapt to different pit dimensions during installation. The adjustable components can be repositioned to match the specific requirements of each installation site, providing versatility without requiring an excessive number of parts.

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If multiple shimming components are used, then alignment can be achieved, but installation time and effort increase significantly

Engineering Contradiction:

Improvealignment precisionVSAvoidinstallation time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The adjustable leg bracket is pre-configured with adjustment mechanisms that allow for precise alignment during installation. The bracket can be adjusted to the correct position before final assembly, eliminating the need for time-consuming shimming operations while achieving the required alignment precision.

Inventive Principle:

Principle #10Preliminary action

4Duration of action of stationary object

If traditional fixed dock levelers are used, then initial installation is straightforward, but maintenance costs and longevity are reduced

Engineering Contradiction:

ImprovelongevityVSAvoidnumber of parts

Core Design Contradiction:

Duration of action of stationary objectVSDevice complexity

Solution Approach 1:

The adjustable leg bracket assembly is designed to accommodate wear and dimensional changes over time. The adjustment mechanisms allow the bracket to be repositioned to compensate for wear, extending the service life of the dock leveler without requiring replacement of multiple parts.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The adjustable bracket system allows the dock leveler to self-correct minor alignment issues and accommodate dimensional changes through its adjustment mechanisms. This self-adjusting capability extends the operational life of the system by maintaining proper alignment and stability without requiring frequent maintenance or replacement of components.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS20240409333A1Dock leveler with adjustable lip keepers

Publication Date: 2024.12.12 OVERHEAD DOOR CORP

AI summary

A dock leveler for a loading dock. In some embodiments, the dock leveler may include a bridge assembly including a deck and a lip extendable from the deck, where the lip is pivotally movable between a stowed position and an extended position. The dock leveler may also include a frame supporting the bridge assembly. The dock leveler may also include a beam and a lip keeper. The beam may include a first end positioned proximate a front edge of the dock. The lip keeper assembly may be configured to selectively secure the lip in the stow position. The lip keeper assembly may be adjustably coupled to the beam permitting adjustment relative to the beam toward or away from the front edge of the dock.