Retrofit Rollerbed With Pneumatic C-Section Panel
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Solution Overview
Problem
Existing rollerbeds are typically installed during vehicle manufacturing and are not easily retrofittable into vans, limiting the ability to conveniently load and unload goods like pallets without a lower floor, which complicates installation and reduces cargo capacity.
Innovation Solution
A rollerbed system with a flat panel and C-sections for increased rigidity, featuring pneumatic reservoirs and push/pull valves to raise and lower rollers, allowing for easy installation and operation without a lower floor, and non-return flaps to prevent inadvertent unloading, utilizing couplers and restraining pins for secure mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a rollerbed is installed during vehicle manufacture, then the rollerbed is securely integrated into the vehicle structure, but the vehicle cannot be retrofitted with a rollerbed after manufacture
Solution Approach 1:
The rollerbed system is divided into separate modular components: a flat panel with C-sections that can be independently installed, rollerbed conveyors that attach to the panel, and pneumatic systems that can be separately fitted. This segmentation enables retrofitting into existing vans without requiring complete vehicle disassembly or reconstruction.
Solution Approach 2:
The rollerbed conveyors are designed to nest within the vehicle's existing structure by attaching to the flat panel that rests on the cargo floor. The C-sections provide structural support while allowing the rollerbed mechanism to be integrated into the available space without requiring a lowered floor or major structural modifications.
2Strength
If a lower floor is used to support pallets, then the rollerbed structure gains rigidity, but the cargo capacity of the vehicle is reduced
Solution Approach 1:
Instead of adding structural support in the vertical dimension by lowering the floor, the solution adds rigidity in the horizontal dimension through C-sections attached to the flat panel. These C-sections extend laterally to provide structural reinforcement while maintaining the original floor height, thus preserving cargo capacity.
Solution Approach 2:
The C-sections provide curved structural reinforcement that increases panel rigidity through their geometric shape. The curved profile of the C-sections distributes loads more effectively than flat supports, providing the necessary strength without requiring additional vertical space.
3Ease of manufacture
If the flat panel is made from sheet material, then the installation is simplified and cargo capacity is maximized, but the panel rigidity is insufficient without additional support structures
Solution Approach 1:
The flat panel is merged with C-sections to create a composite structure. The sheet material panel provides the basic supporting surface while the C-sections attach to its underside to provide the necessary rigidity. This combination achieves both installation simplicity and structural strength.
Solution Approach 2:
The panel assembly uses composite construction combining sheet material with C-section structural elements. This composite structure leverages the advantages of both materials: the ease of installation and cargo capacity of sheet material, and the rigidity and strength of the C-section structural supports.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables convenient retrofitting of rollerbeds into vans, improving pallet loading and unloading efficiency, maximizing cargo capacity, and simplifying installation while preventing cargo movement during vehicle operation.
Implementation Method 1
pneumatic reservoirs located within 'top-hat' sections
Data Source
AI summary
There is disclosed a rollerbed 150, 160 that may be fitted to vehicles such as vans 100. The rollerbed 150 comprises a substantially flat panel 300 that is provided with strengthening "C" sections 310 along the sides. Rollers 370 may be lifted up, so as to project through apertures in the panel 300, by inflating air sacs 350a, 350b, 750a, 750b. Air reservoirs 330a-330f, 730a-730f are preferably located in top hat sections 320a-320f. The top hat sections 320 further strengthen the panel 300. A non-return flap 210 may be provided to prevent inadvertent unloading of cargo such as a pallet 600. Pneumatic control valves 155 are preferably arranged so that when the doors of the vehicle are closed, the rollers 370 are lowered. Pins 170 are preferably provided to restrain the rollcrbcd 150, 160 relative to wheel wells 115 of the van 100. The rollcrbcd preferably comprises a mastcr portion 150 and a slave portion 160.