Detachable Pallet Truck Frames for Compact Container Shipping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing pallet truck vehicles require complete assembly at the point of manufacture for shipping, leading to inefficient use of space in shipping containers due to their large packing configurations, which are either fully assembled or partially disassembled with disconnected handles, resulting in high transportation costs.
Innovation Solution
A modular design where the front and rear frames of the vehicle are detachable, allowing for separate packaging and assembly post-shipping, with only hydraulic and electrical connections required after delivery, utilizing a unique packing system that nests frames in a compact configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If vehicles are completely assembled at the point of manufacture for shipping, then the vehicle structure is complete and ready for use, but the space occupied in height, length and width for each two vehicles becomes relatively large
Solution Approach 1:
The vehicle is divided into separable front and rear frame assemblies that can be detached from each other. The front frame includes forks and connecting rod assembly, while the rear frame includes the motor and drive wheel. This segmentation allows each component to be packed separately in a nested configuration, significantly reducing the packing volume compared to shipping fully assembled vehicles.
2Length of stationary object
If the operator handle is structurally disconnected at its base and located in a horizontal position to reduce height, then the vehicle height is reduced, but the width and length remain similar to fully assembled vehicles
Solution Approach 1:
The handle is separated from the rear frame assembly and can be independently positioned. When packed, the handle is placed in a horizontal position and nested within the space occupied by other components, rather than extending vertically. This segmentation allows the handle to contribute minimally to the overall packing dimensions.
Solution Approach 2:
The front frame assemblies are nested within the rear frame assemblies, with the forks of one vehicle positioned within the space of another vehicle's frame. The handles are also nested horizontally within the overall packing structure. This nesting arrangement maximizes space utilization and minimizes the external dimensions of the packed configuration.
3Volume of stationary object
If two vehicles are arranged with forks overlying each other and front frames connected to rear frames, then width and height are reduced, but the combined length remains similar to fully assembled vehicles
Solution Approach 1:
The front and rear frames are segmented and can be independently positioned during packing. This allows the forks to be oriented vertically with one set overlaying another, while the frame bodies are arranged horizontally. The segmentation enables this three-dimensional arrangement that optimizes all three dimensions of the packing volume.
Solution Approach 2:
The packing arrangement utilizes all three spatial dimensions efficiently. The forks are arranged in the vertical dimension (one overlaying another), while the frame bodies are arranged in the horizontal plane. This multi-dimensional arrangement reduces the footprint in all directions compared to traditional linear packing of assembled vehicles.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Packing system (300) and method for shipping pallet truck vehicles (V) wherein each vehicle has a front frame (2') configured to be assembled to a rear frame (1'). The packing system (300) includes a first holder (400) that holds a plurality of vehicle rear frames (1') lying on their sides, a second holder (500) that holds a plurality of vehicle front frames (2') having forks with at least a first front frame upright and having the forks facing in a first direction, and holds at least a second front frame (2') inverted and having the forks facing in an opposed second direction, and wherein the first holder (400) holding the plurality of rear frames is disposed within the second holder vertically between the forks of the upright at least one first front frame and the forks of the inverted at least one second front frame.