Movable Pallet Platform for Ergonomic High-Density Storage Access
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Solution Overview
Problem
Pallet-based article handling systems often lead to musculoskeletal injuries and reduced productivity due to the need for pickers to bend and reach to access items from the back of pallets, especially in high-density storage environments, where additional space or redesign of racks is costly and inefficient.
Innovation Solution
An article support platform integrated into or connected with a pallet, featuring a repositionable load-bearing surface that allows for shifting or rotating sections to enhance access, reducing the need for pickers to reach and bend by reorienting the platform to bring articles closer to the picker.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If articles are stored on pallets in pallet racks with tight spacing for high-density storage, then storage density is improved, but picker accessibility to articles at the back of pallets deteriorates, requiring bending and reaching which causes musculoskeletal injuries
Solution Approach 1:
The platform is designed with a movable second portion that can be repositioned relative to the first portion. This dynamic reconfiguration allows the platform to adapt its configuration based on picking needs, enabling pickers to access articles more easily without compromising the high-density storage arrangement in tight rack spacing environments
Solution Approach 2:
The platform is divided into multiple portions (first portion and second portion) that can be independently positioned. The second portion can be moved to different locations on the platform, allowing selective access to different areas of the pallet while maintaining the compact storage configuration
2Ease of operation
If additional space is provided about the top and/or sides of the pallet to improve picker access, then ease of operation is improved, but warehouse storage density deteriorates
Solution Approach 1:
Instead of providing permanent additional space, the platform uses a movable second portion that can be repositioned dynamically. This allows the platform to create accessible configurations only when needed, maintaining maximum storage density in the warehouse while providing adequate picker access during operations
3Ease of operation
If pickers are lifted to the level of items by forklift in high-density storage applications, then accessibility to articles is improved, but safety risks increase requiring tethering which interferes with picking productivity
Solution Approach 1:
The movable second portion allows the platform to reconfigure itself to present articles in more accessible positions. This reduces the need for pickers to be lifted to high positions, thereby eliminating the safety tether requirement while maintaining article accessibility and improving picking productivity
4Ease of manufacture
If the platform structure is made fixed and simple for easy manufacture, then ease of manufacture is improved, but adaptability for different picking configurations deteriorates
Solution Approach 1:
The platform is segmented into multiple portions that can be independently manufactured and then assembled. This segmentation allows each portion to be manufactured using simple, standardized processes while the overall assembly provides the necessary adaptability through the movable connection between portions
Solution Approach 2:
The platform incorporates simple movable mechanisms that allow the second portion to be repositioned relative to the first portion. These dynamic elements are designed to be easily manufactured while providing the adaptability needed for different picking configurations and article arrangements
Data Source
AI summary
An apparatus includes a platform positioned on the pallet, the platform having a load bearing surface including a first portion and a second portion. The second portion is movable relative to the first, such that the second portion overlies the first portion. A method of unloading articles from a pallet including arranging the loaded pallet with the second portion of the platform in the second position, unloading articles from the first portion of the platform, shifting the second portion of the platform to the second position, and unloading articles from the second portion of the platform. A method of loading articles on a pallet, including arranging the pallet with the second portion of the platform in the second position, loading articles onto the second portion of the platform, shifting the second portion of the platform to the first position, and loading articles onto the first portion of the platform.