Pallet Truck Packing System Using Modular Frame Nesting
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Solution Overview
Problem
Conventional electric pallet truck vehicles are typically shipped in fully assembled configurations, leading to inefficient use of space in shipping containers and requiring complex assembly and disassembly processes, which are time-consuming and costly.
Innovation Solution
A modular design where the front and rear frames of the pallet truck vehicle are easily detachable and reattachable, allowing for a compact and efficient packing system where the rear frames are stored on their sides and the front frames are stacked upright or inverted, reducing the overall dimensions and facilitating quicker assembly post-shipping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vehicles are shipped in fully assembled configurations, then the vehicle structure is complete and ready for use, but the space occupied in shipping containers increases significantly
Solution Approach 1:
The vehicle is divided into separable components (front frame with forks and rear frame with handle) that can be detached from each other. This segmentation allows the components to be packed separately in a nested configuration, significantly reducing the shipping volume while maintaining the capability to reassemble into a fully functional vehicle upon delivery.
2Length of stationary object
If the operator handle is structurally disconnected and positioned horizontally to reduce height, then the vehicle height is reduced for better packing, but the assembly complexity increases
Solution Approach 1:
The operator handle is pre-configured in a horizontal position during manufacturing, and the connection points are pre-prepared with alignment features. This preliminary configuration reduces the height for optimal packing while maintaining simple assembly procedures, as the handle only needs to be rotated to the operational position and connected without complex alignment requirements.
3Volume of stationary object
If vehicles are packed with forks overlying each other to reduce width and height, then the packing density improves, but the risk of damage to fork components increases
Solution Approach 1:
The front frames with forks are nested within the rear frames in a nested doll configuration. The forks of one vehicle are positioned within the protective envelope of the rear frame of another vehicle, allowing high packing density while the outer frames protect the delicate fork components from damage during shipping.
4Reliability
If hydraulic oil pipe and electrical wiring connections are made between front and rear frames, then the vehicle functions are integrated, but the assembly time and cost increase
Solution Approach 1:
The hydraulic oil pipes and electrical wiring connections are extracted from the permanent assembly and converted into detachable quick-connect interfaces. This allows the front and rear frames to be connected and disconnected rapidly without requiring time-consuming assembly of rigid pipes and wiring harnesses, significantly reducing assembly time while maintaining full system functionality.
Data Source
AI summary
Packing system and method for shipping pallet truck vehicles wherein each vehicle has a front frame configured to be assembled to a rear frame. The packing system includes a first holder that holds a plurality of vehicle rear frames lying on their sides, a second holder that holds a plurality of vehicle front frames 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 inverted and having the forks facing in an opposed second direction, and wherein the first holder 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.