Dock Leveler Stop and Lock Mechanism
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Solution Overview
Problem
Vertically storing dock leveler decks experience rocking motion and wear at pivotal connections when held upright, necessitating a more reliable stop and locking mechanism for secure positioning and maintenance.
Innovation Solution
A combination stop-and-lock mechanism with a threaded connection for adjustable stopping and a removable blocking pin, allowing for positive stopping and locking of the deck at its vertically stored position, preventing unintended descent and providing relative sliding motion for secure operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the hydraulic cylinder is used to hold the deck at its vertically stored position by fully extending the piston rod, then the deck can be positioned upright, but the radial pin clearance at the various pivotal connections allows the deck to rock back and forth before settling
Solution Approach 1:
The patent applies preliminary anti-action by providing a positive stop mechanism that prevents the harmful rocking motion before it occurs. The stop mechanism engages with the deck at the vertically stored position to counteract the instability caused by radial pin clearance, eliminating the need for the deck to rock and settle before achieving a stable position.
Solution Approach 2:
The patent introduces an intermediary element - a separate stop mechanism - that mediates between the hydraulic cylinder's positioning action and the deck's final stable position. This intermediary component absorbs the instability from pin clearance and provides a positive stop, preventing the deck from rocking while maintaining the desired upright position.
2Reliability
If a redundant locking mechanism is added to prevent unexpected deck descent during servicing, then safety is improved, but device complexity increases
Solution Approach 1:
The patent merges the stop and lock functions into a single integrated mechanism. The stop mechanism that prevents rocking motion also serves as the locking mechanism that secures the deck during servicing. By combining these two functions, the patent achieves redundant protection against unexpected descent without significantly increasing device complexity.
Solution Approach 2:
The patent applies universality by designing a mechanism that performs multiple functions: it provides a positive stop to prevent rocking, acts as a lock to secure the deck during servicing, and works with the hydraulic cylinder's positioning action. This multi-functional approach achieves reliability improvement without adding separate complex locking components.
Data Source
AI summary
A dock leveler with a pivotal deck includes a stop mechanism that provides the deck with a positive stop at the deck's vertically stored position without the deck's actuator having to be fully extended. With the actuator being less than fully extended, the stop mechanism and actuator can exert opposing forces that help prevent the deck from rocking back and forth as the deck settles to its stationary, upright position. In some cases, the stop mechanism is part of a combination stop-and-lock mechanism that includes a locking device for temporary providing a redundant or alternate lock that prevents the deck from descending unexpectedly while the dock leveler is being serviced or repaired.