Pallet Stacker With Bottom-Lift Mechanism for Stable Fast Stacking
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Solution Overview
Problem
Storing empty pallets occupies valuable floor space and stacking them inefficiently takes time, especially when ensuring stability.
Innovation Solution
A pallet stacker with a corral and lifting mechanism that engages a bottom pallet to lift and lower a stack of pallets, allowing new pallets to be inserted below, featuring a latch that pivots and slides vertically, and is operated by a hydraulic system with a user interface and presence sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual stacking of pallets is used, then stability can be ensured, but time consumption increases
Solution Approach 1:
The stacking machine performs the stacking operation automatically without requiring manual intervention for each stacking action. The system uses sensors to detect pallet positions and automatically controls the lifting mechanism to stack pallets, making the system self-sufficient and eliminating time-consuming manual operations while maintaining stability through controlled automated movements.
Solution Approach 2:
The patent replaces manual mechanical stacking operations with an automated lifting mechanism that uses hydraulic or electric actuators. The lifting mechanism automatically raises and lowers the pallet stack, substituting manual labor with mechanical automation to reduce time consumption while ensuring stable stacking through precise control of the lifting motion.
2Reliability
If pallets are stacked manually, then stability can be verified, but labor requirements increase
Solution Approach 1:
The system automatically verifies stack stability through integrated sensors that detect pallet positions and stacking alignment. The machine self-adjusts and self-corrects during the stacking process, eliminating the need for manual verification while maintaining high reliability through automated sensing and control systems.
Solution Approach 2:
The patent incorporates sensors that provide real-time feedback on pallet positioning and stack stability. This feedback loop allows the control system to automatically adjust the lifting mechanism and stacking parameters to maintain stability, replacing manual verification with automated sensing and control.
3Ease of operation
If floor space is used for storing pallets, then accessibility is improved, but space efficiency decreases
Solution Approach 1:
The patent transitions from horizontal floor storage to vertical stacking storage. By using the vertical dimension for pallet storage, the system eliminates the need for extensive floor space while maintaining easy accessibility through the automated lifting mechanism that can raise and lower stacks vertically. This dimensional transition solves the space-efficiency problem while preserving operational ease.
Solution Approach 2:
The automated lifting mechanism provides self-service by automatically retrieving and positioning pallets from the vertical stack. The system uses sensors and automated control to access pallets without requiring manual intervention, maintaining ease of operation while utilizing vertical space instead of floor space.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Efficiently stacks and stores pallets, saving space and time, while ensuring stability and safety through controlled lifting and lowering operations.
Implementation Method 1
a piston and hydraulic cylinder connected to a main bracket vertically slidably connected to a slide
Implementation Method 2
the latch engages a cam surface that moves the latch between a deployed position and a retracted position
Data Source
AI summary
A pallet stacker according to an example embodiment includes a corral defining an interior storage space configured to retain a stack of pallets. At least one lifting mechanism is configured to engage a bottom pallet of the stack of pallets, to lift the stack of pallets to permit insertion of at least one new pallet below the stack of pallets, and to lower the stack of pallets onto the new pallet.