Layered Fork Tine With Cavity for Lightweight Logistics Vehicles
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Solution Overview
Problem
Existing fork tines are heavy, costly to produce, and prone to deformation due to welding, requiring skilled labor and large logistics vehicles to prevent tipping.
Innovation Solution
A modular design with a top layer and rear layer forming a cavity, joined by screws, allowing for lightweight construction, space for sensors, and easy assembly without welding, using thin-walled sheets and reinforcing elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fork tines are made from solid material using forging process, then strength and structural integrity are improved, but weight increases significantly
Solution Approach 1:
The fork tine is divided into multiple layers (blade layer, shank layer, heel layer) that are joined together through fastening means. This segmentation allows each layer to be optimized independently and reduces the overall material usage compared to solid forging, achieving weight reduction while maintaining structural integrity through the distributed fastening system.
2Weight of moving object
If fork tines are made from multiple layers joined by welding, then weight is reduced, but deformation occurs due to high heat exposure
Solution Approach 1:
The welding process (thermal joining) is replaced with a mechanical fastening system using fastening means such as bolts, screws, or rivets. This substitution eliminates the high heat exposure that causes deformation and distortion, while still achieving strong structural connection between the layered components through mechanical interlocking and clamping forces.
3Ease of manufacture
If fork tines are made from multiple layers joined by welding, then production cost is reduced, but skilled welders are required driving up costs
Solution Approach 1:
The fork tine is segmented into separate layers that can be manufactured independently using standard fabrication processes, then assembled using simple mechanical fastening. This segmentation enables parallel production of components and eliminates the need for specialized welding operations, reducing both labor skill requirements and production complexity while maintaining manufacturing efficiency.
4Force
If traditional solid fork tines are used, then load capacity is sufficient, but logistics vehicle size must be large to prevent tipping
Solution Approach 1:
The segmented layered structure with strategic fastening provides sufficient load capacity through distributed stress paths and mechanical interlocking, enabling the use of more compact logistics vehicles without compromising lifting capability or stability.
5Productivity
If welding is used to join fork tine components, then production is faster, but thermal distortion prevents further use of fork tines
Solution Approach 1:
The mechanical fastening system replaces welding operations, eliminating thermal distortion that renders fork tines unusable. The assembly process uses pre-drilled holes and fastening means that can be quickly installed, maintaining high production speed while ensuring the structural integrity and reliability of the final product without heat-induced deformation.
Data Source
AI summary
A fork tine for preferably automated logistics vehicles include at least a shank, a heel and a blade. Fastening elements for attachment to a logistics vehicle are arranged on the shank. To form a cavity, the fork blade is made from a top layer and a rear layer which are joined, in particular screwed together, by fasteners, in particular screws.