Roll Tarp System with Manual Crank Backup
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Solution Overview
Problem
Conventional tarp systems for open top containers are time-consuming, expensive, and difficult to operate, especially when covering large or heavily loaded containers, and often fail to completely seal the contents due to mechanical issues or require manual operation after mechanical failure.
Innovation Solution
A roll tarp system that uses a roll pipe and arm assembly with a power mechanism and flexible arm sections to efficiently cover and uncover the container, featuring a latching mechanism for secure closure and a manual operation option in case of mechanical failure, allowing for easy operation from ground level.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cable-pulley systems are used to cover open top containers, then the container can be covered, but it takes a long time to cover or uncover the container and reduces the open area for loading
Solution Approach 1:
The patent employs a dynamic roll pipe system that can rotate and reciprocate along the container to deploy and retract the tarp quickly. The roll pipe rotates to unroll the tarp during covering and rotates in reverse during uncovering, enabling rapid response without the time-consuming cable-pulley mechanism. This dynamic operation directly addresses the productivity and time loss contradiction.
Solution Approach 2:
The patent extracts the tarp storage function from the front of the container (where cable-pulley systems store tarps) and relocates it to a dedicated housing at the rear or side of the container. This extraction eliminates the obstruction to loading operations while maintaining quick tarp deployment capability, resolving the contradiction between covering speed and loading area.
2Ease of operation
If heavy torque tubes are used in side flip systems to cause the back arms to flip the tarp, then the tarp can be flipped, but the system becomes heavy thus reducing payload
Solution Approach 1:
The patent replaces the heavy mechanical torque tube system with a more efficient actuator mechanism. The actuator is connected to the roll pipe and provides controlled rotational force to deploy and retract the tarp, eliminating the need for heavy torque tubes while maintaining full tarp flipping capability. This substitution directly reduces system weight and increases payload capacity.
Solution Approach 2:
The patent changes the operational parameters of the tarp system by using a compact actuator with optimized force application points. Instead of relying on the mechanical advantage of long torque tubes, the system uses direct actuation with controlled force and speed parameters, achieving the same tarp flipping function with significantly reduced weight.
3Reliability
If manual operation is required after mechanical failure of tarp systems, then the system can still operate, but it requires operators to climb to the top of the container which is inconvenient or difficult
Solution Approach 1:
The patent incorporates a manual crank mechanism that enables the operator to service the system from ground level. The manual crank is connected to the roll pipe through a gear reduction mechanism, allowing the operator to rotate the roll pipe and deploy or retract the tarp without climbing. This self-service capability maintains operation continuity while eliminating the need for dangerous climbing operations.
Solution Approach 2:
The patent introduces a manual crank as an intermediary device between the operator and the roll pipe mechanism. The crank provides mechanical advantage through its handle and connects to the roll pipe through a coupling mechanism, translating ground-level operator input into roll pipe rotation. This intermediary enables reliable manual operation without requiring the operator to access the top of the container.
Data Source
AI summary
A system for selectively covering a container with a tarp. The system includes a roller and a tarp connected to the roller. A motor is connected to an output member, and the output member is releasably engaged with the roller. Actuation of the motor when the output member and the roller are engaged causes movement of the roller relative to the tarp. A crank is releasably connected with the roller, wherein one of the crank and the roller is connected to a coupler and the other of the crank and the roller is connected to a joint. When the output member and the roller are disengaged and the crank is connected with the roller, rotation of the crank causes movement of the roller relative to the tarp.