Modular deck system for use with movable platforms
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Solution Overview
Problem
The traditional method of loading and unloading freight from semi-trailers is inefficient, as it requires multiple handling operations and results in wasted time and capacity due to the need for frequent forklift trips and lack of easy modification or stacking of pallets, leading to reduced operational speed and increased handling costs.
Innovation Solution
A modular deck system featuring a movable platform with adjustable vertical posts and engagement members that allow decks to be placed at various heights, enabling easy stacking and bulk movement of freight, and an extension post system for securing tall cargo, which can be locked in place to prevent dislodgement during transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional forklift loading/unloading method is used, then freight can be handled, but multiple handling operations and frequent trips are required, reducing operational speed
Solution Approach 1:
The system divides the trailer interior into multiple deck levels using horizontal deck members that can be positioned at different heights. This segmentation allows freight to be stacked vertically across multiple levels, enabling bulk loading and unloading operations rather than handling individual pallets sequentially, thereby reducing the number of trips required.
Solution Approach 2:
The invention transitions from traditional single-level floor loading to multi-level vertical stacking by introducing adjustable deck members at various heights. This dimensional change from 2D floor space to 3D vertical space utilization allows simultaneous access to multiple loading zones and enables bulk material movement, significantly improving operational speed.
2Adaptability or versatility
If traditional fixed floor loading is used, then freight can be loaded, but easy modification or stacking of pallets is not possible, leading to unused capacity
Solution Approach 1:
The system employs adjustable vertical posts with movable engagement members that can be repositioned along the posts, and deck members that can be moved between different height positions. This dynamic configurability allows the loading structure to adapt to various freight types, sizes, and stacking requirements, maximizing trailer capacity utilization while maintaining versatility.
Solution Approach 2:
The vertical posts and deck members serve multiple functions: providing structural support, enabling adjustable height configurations, facilitating pallet stacking at different levels, and allowing easy modification of the loading arrangement. This multi-functionality addresses both adaptability requirements and capacity optimization simultaneously.
3Productivity
If multiple forklift drivers are used to unload simultaneously, then unloading speed increases, but equipment and labor costs increase
Solution Approach 1:
By segmenting the trailer into multiple accessible deck levels with open-sided construction, the system allows a single forklift to efficiently service multiple loading zones sequentially or simultaneously at different heights, reducing the need for multiple forklifts while maintaining high unloading speed.
Solution Approach 2:
The multi-level deck structure enables continuous loading and unloading operations by allowing the forklift to move between levels without requiring the trailer to be repositioned or reconfigured, maintaining constant productive action with minimal equipment.
4Productivity
If forklift enters and exits trailer frequently, then pallets can be removed, but driver safety concerns increase and process speed decreases
Solution Approach 1:
By utilizing vertical stacking with multiple deck levels, the system allows pallets from different levels to be accessed and removed simultaneously or in sequence without requiring the forklift to repeatedly enter and exit the trailer, reducing safety risks while improving overall removal efficiency.
Data Source
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AI summary
Disclosed herein is a modular deck system that utilizes a combination of a movable platform having a plurality of vertical posts with engagement members. Decks, filled with freight, can be placed onto the vertical posts at various heights at different sections of the movable platform using a conveyance vehicle. Further, the height of the vertical posts can be extended using an extension post for securing tall cargo. The decks can also be locked to the vertical posts to prevent dislodgement of the deck during transport of the movable platform.