Pallet Mover Wheel Layout for Stepping Over Lower Deck Planks
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing pallet movers, particularly autonomous ones, face challenges in efficiently inserting forks into pallets due to the need for wheels to physically ride over planks in the lower deck, which can cause damage and require excessive force, leading to complexity and weight limitations.
Innovation Solution
A pallet mover design with independently movable first and second sets of wheels that can step over planks by vertically retracting and deploying, with the first set bearing the load and the second set stabilizing to prevent tipping, allowing seamless insertion without physical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wheels are mounted on the inside of the forks to prevent tipping, then the pallet truck can lift heavy loads, but the wheels must physically ride over planks in the lower deck causing damage and requiring excessive force
Solution Approach 1:
The wheel assembly is divided into two independent sets: a first set of wheels mounted on the forks for load bearing, and a second set of wheels mounted on the main body for stabilization. This segmentation allows each set to perform its specific function without interfering with the other, eliminating the need for wheels to ride over pallet planks
Solution Approach 2:
The stabilizing function is extracted from the fork-mounted wheels and transferred to a separate second set of wheels mounted on the main body. This extraction removes the harmful interaction between wheels and pallet planks while maintaining the tipping prevention function
2Strength
If the main body is made intentionally heavy to counterbalance loads, then the powered pallet truck can lift heavier pallets, but the overall weight and complexity of the device increases
Solution Approach 1:
Instead of adding weight to the main body for counterbalancing, the patent uses the second set of wheels positioned on the main body to provide counterbalancing through their placement and interaction with the ground, eliminating the need for additional weight
Solution Approach 2:
The passive weight-based counterbalancing system is replaced with an active mechanical system using the second set of wheels and their positioning to achieve counterbalancing, reducing overall device weight
3Speed
If front wheels are mounted on levers connected to the hydraulic jack, then the pallet truck can raise forks vertically, but the linkages force front wheels down requiring additional mechanical complexity
Solution Approach 1:
The front wheels are extracted from the lever-linkage system and remounted directly on the forks. This extraction eliminates the complex linkages connecting wheels to the hydraulic jack while maintaining the fork lifting function through direct hydraulic actuation
Data Source
AI summary
A pallet mover for moving a pallet, the pallet comprising: a top deck and a lower deck formed from one or more planks, the lower deck being spaced apart from the top deck, and the pallet mover comprising: a main body comprising a lifting mechanism and a drive assembly for moving the pallet mover; a plurality of forks for lifting and handling pallets, the plurality of forks outwardly extending from the main body and configured to be lifted by the lifting mechanism; and an independently movable first set of wheels and an independently movable second set of wheels, the first set of wheels configured to move vertically to disengage and engage with the floor, such that the first set of wheels are configured to step over the one or more planks of the pallet when the plurality of forks are inserted into the pallet.