Pressed Fork Structure for Pallet Trucks
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Solution Overview
Problem
Conventional pallet truck forks are constructed using welded steel, which can lead to weaker weld joints and limited maneuverability due to restricted clearance height, affecting their strength and operational efficiency.
Innovation Solution
A pressed and non-welded fork structure with an elongated body and integral outboard end portion, featuring a top wall, sidewalls, and a tip sidewall for guiding entry beneath pallets, along with a bumper providing increased clearance distances to prevent operator foot contact and accommodate drive wheels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welded steel construction is used for pallet truck forks, then the structural integrity is maintained, but the weld joints become weaker than the parent material
Solution Approach 1:
The patent removes the welding process entirely from the fork construction. The fork is formed as a single pressed steel piece without any weld joints, extracting the problematic welding step while maintaining structural integrity through cold-forming techniques.
Solution Approach 2:
The patent changes the manufacturing parameter from thermal welding to cold pressing. By altering the fabrication method from joining separate pieces with welds to forming a single-piece structure through pressing, the weakness of weld joints is eliminated while maintaining or improving overall strength.
2Object-affected harmful factors
If the clearance height is reduced to protect operators from foot contact, then operator safety is improved, but the maneuverability of the pallet truck is limited
Solution Approach 1:
The patent introduces a bumper component that extends horizontally from the fork assembly, creating a protective barrier in the horizontal dimension rather than relying solely on vertical clearance height. This dimensional shift allows the truck to maintain adequate vertical clearance for maneuverability while providing horizontal protection for operators.
3Object-affected harmful factors
If the clearance height is reduced, then the risk of foot contact is decreased, but the clearance for drive wheels is also reduced
Solution Approach 1:
The bumper extends in the horizontal direction to provide foot protection, decoupling the safety function from the vertical clearance height. This allows the vertical clearance to be minimized for foot protection while the horizontal bumper extension provides the necessary protection without interfering with drive wheel clearance.
Data Source
AI summary
A pallet truck has a pressed and non-welded fork structure. The fork structure includes an elongate body portion and an outboard end portion integrally formed with the body portion. The body portion has a top wall and opposing sidewalls integrally formed with the top wall. The outboard end portion projects from the body portion and includes a tip sidewall defining a tip region for guiding entry of a fork assembly beneath a pallet.