Rotating Lever Pallet Stacking System for Rack Integration
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Solution Overview
Problem
Existing pallet stacking systems face limitations in efficiently managing empty pallets, including limited capacity, complex machinery requirements, and space occupancy, which complicates logistics operations and maintenance.
Innovation Solution
A pallet stacking system utilizing two sets of rotating levers with axes of rotation, allowing for efficient stacking and removal of empty pallets within a pallet rack structure without the need for electromechanical drives, thus simplifying operations and reducing space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional stackers are installed on the ground or close to the ground, then they can be supported by the ground or larger structure, but they occupy large space and require complex electromechanical drives
Solution Approach 1:
The patent transitions from ground-level stacking to rack-integrated stacking, moving the system into the vertical dimension of the rack structure. The levers are mounted on rack beams at elevated positions, eliminating the need for ground-level support structures and reducing floor space occupancy while maintaining structural support through the rack itself.
Solution Approach 2:
The patent extracts the support function from ground structures and relocates it to the rack structure itself. The levers are directly mounted on rack beams, utilizing the rack as the support structure, thereby eliminating the need for separate ground-based support systems and reducing overall space requirements.
2Quantity of substance
If the number of empty pallets accumulated on a stacker is increased, then more pallets can be stored, but more stackers must be added with extra machinery costs
Solution Approach 1:
The rack structure serves multiple functions: it provides storage for pallets, supports the stacking mechanism, and eliminates the need for separate ground-level stackers. By integrating the stacking function into the rack structure, the system can accumulate more pallets vertically without adding horizontal space requirements or complex machinery.
Solution Approach 2:
The system utilizes the vertical dimension of the rack structure to accumulate pallets in stacks, rather than spreading them out horizontally on ground-level stackers. This vertical stacking approach increases pallet capacity without requiring additional machinery or horizontal space.
3Productivity
If conventional stackers are used, then pallets can be stacked, but additional transport and handling processes are required to move pallet blocks to storage areas
Solution Approach 1:
The patent combines the stacking function with the storage function by integrating the levers directly into the rack structure. Pallets are stacked directly into the rack storage positions, eliminating the need for separate transport operations to move pallets from stackers to storage areas, thereby reducing handling time and improving productivity.
4Ease of operation
If forklift operators manually place pallets, then visibility of pallet height can be maintained, but the system becomes labor-intensive and less efficient
Solution Approach 1:
The lever system is designed to automatically engage with pallets and guide them into the correct stacking positions. The mechanical design of the levers provides self-guiding functionality, reducing the need for manual operator intervention while maintaining control over pallet placement, thereby improving productivity without sacrificing operational ease.
Data Source
AI summary
A pallet stacking system on a structure comprises two sets of rotating levers and two axes of rotation, each axis of rotation corresponding to each set of rotating levers. The axes of rotation are inserted in a structure and parallel and at the same, with height between them, and at the same time the axes of rotation are separated by a distance, with sufficient free space for the passage of a horizontal pallet between them. The levers are distributed along the corresponding axis of rotation thereof and concentrically articulated about that same axis of rotation and with the capacity to rotate. The levers have a rest position, resulting in levers enabled at the same time to both receive and hold at least one pallet in the rest position.