Replaceable Pallet Support Leg for Secure Order Picker Locking
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Solution Overview
Problem
Existing pallets face challenges in providing durability, stability, and repairability while being subjected to repeated use with pallet-securing mechanisms on lift vehicles, and there is a need for a construction that is easy to manufacture and assemble.
Innovation Solution
A pallet design featuring a top and bottom deck interconnected by support legs, with at least one replaceable leg configured to engage a pallet securing device on a material handling vehicle, utilizing textured surfaces and converging vertical walls to enhance secure locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pallets are constructed from plastic materials to improve durability and impact performance, then durability is improved, but resistance to deformation and structural stability become challenging to replicate
Solution Approach 1:
The pallet combines plastic materials with metal support legs to create a composite structure. The plastic provides durability and impact resistance, while the metal legs provide structural strength and resistance to deformation. This composite approach resolves the contradiction by leveraging the complementary properties of different materials.
Solution Approach 2:
The pallet is divided into separate functional components: plastic decks for load-bearing and plastic protection, metal support legs for structural strength, and replaceable engagement portions for securing mechanisms. This segmentation allows each component to be optimized for its specific function, with metal legs providing the necessary resistance to deformation while plastic parts provide durability.
2Stability of the object's composition
If pallets are constructed with traditional integrated support legs to maintain structural integrity, then structural stability is maintained, but repairability and ease of replacement of worn components deteriorate
Solution Approach 1:
The support legs are segmented into permanent structural portions and replaceable engagement portions. The permanent portions maintain structural integrity when connected to the decks, while the replaceable portions can be independently replaced when worn by pallet-securing mechanisms. This segmentation enables both structural stability and ease of repair.
Solution Approach 2:
The support legs transition from being entirely permanent to having replaceable portions, changing the lifecycle parameter of specific components. The replaceable engagement portions have a designed service life and are replaced when worn, while the permanent structural portions remain in service indefinitely, maintaining structural integrity throughout the pallet's life.
3Ease of manufacture
If pallets use fixed support legs with integrated securing engagement to simplify construction, then ease of manufacture is improved, but durability and resistance to wear from securing mechanisms deteriorate
Solution Approach 1:
The support legs are divided into permanent structural portions that provide durability and resistance to wear, and replaceable engagement portions that absorb wear from pallet-securing mechanisms. This segmentation maintains ease of manufacture through modular construction while significantly improving reliability by protecting the permanent portions from wear.
Solution Approach 2:
The replaceable engagement portions are designed as consumable components that are replaced when worn, similar to disposable parts. These portions are optimized for cost-effective replacement rather than long-term durability, allowing the expensive permanent structural portions to remain in service indefinitely, thus improving overall reliability while maintaining ease of manufacture.
4Ease of repair
If pallets are designed with replaceable components to improve repairability and reduce wear, then ease of repair and durability are improved, but device complexity and manufacturing assembly difficulty increase
Solution Approach 1:
The support legs are segmented into permanent and replaceable portions with standardized connection interfaces. This segmentation enables easy replacement of worn components while maintaining overall structural simplicity. The modular design with defined connection points minimizes assembly complexity compared to fully integrated designs.
Solution Approach 2:
The permanent support leg portions serve multiple functions: providing structural strength, supporting the decks, and offering attachment points for replaceable engagement portions. This multi-functionality reduces the need for additional components, thereby reducing overall device complexity while enabling easy repair through replacement of only the worn engagement portions.
Data Source
AI summary
A pallet comprising a top deck and a bottom deck interconnected via a plurality of support legs that maintain the top deck and bottom deck in spaced relationship, defining fork receiving openings along a lateral edge of the pallet between the support legs, and wherein at least one support leg comprises an optionally replaceable component that is configured to engage a pallet securing device on a material handling vehicle to enable the pallet securing device to lock the pallet to the vehicle. Also, an optionally replaceable support leg for interconnecting upper and lower decks of a pallet, the support leg being configured to engage a pallet securing device on a material handling vehicle to enable the pallet securing device to lock the pallet to the vehicle.