Shimless Dock Leveler Frame Adjustment
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Solution Overview
Problem
The installation of dock levelers into pits is time-consuming and imprecise due to the need for shimming to account for manufacturing tolerances and pit depth variances, limiting the ability to achieve a perfectly level deck with the surrounding dock floor.
Innovation Solution
A shimless frame support system that includes a pit-supported portion and a deck-supporting portion, connected by an adjusting assembly allowing for precise leveling of the dock leveler deck with respect to the surrounding dock floor, eliminating the need for shims.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If shims are used to level the dock leveler frame, then the deck can be leveled with the surrounding dock floor, but the installation process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent removes shims entirely from the leveling process by integrating adjustment capability directly into the frame structure. The frame includes an adjustable support portion that can be positioned at different heights to achieve leveling without requiring separate shim components, thereby eliminating the time-consuming process of selecting and installing multiple shim thicknesses.
Solution Approach 2:
The frame incorporates an adjustable support portion that can dynamically change its position along the vertical axis to accommodate different pit depths and achieve proper decking alignment. This dynamic adjustment mechanism replaces the static, discrete thickness options of shims with a continuous or multi-position adjustment capability.
2Manufacturing precision
If discrete thickness shims are used, then some leveling can be achieved, but the precision is limited by the available shim thicknesses
Solution Approach 1:
The adjustable support portion can be positioned at multiple discrete heights or continuously along a vertical range, providing a spectrum of adjustment options that exceeds the limited discrete thicknesses of traditional shims. This allows precise leveling even when the required adjustment falls between standard shim thicknesses.
Solution Approach 2:
The frame's support portion is designed to be dynamically adjustable to different positions, enabling adaptation to a wide range of pit depths and decking requirements. This dynamic capability provides superior versatility compared to fixed-thickness shims.
3Adaptability or versatility
If multiple shims of various thicknesses are brought to the installation site, then preparation for different variance scenarios is improved, but the device complexity and inventory requirements increase
Solution Approach 1:
The adjustable support portion serves multiple functions: it provides structural support for the deck, enables leveling across a wide range of pit depths, and accommodates manufacturing tolerances. This single multi-functional component replaces the need for multiple shim components of varying thicknesses.
Solution Approach 2:
The patent eliminates the need for separate shim inventory by integrating the leveling function directly into the frame's support structure. The adjustable support portion inherently provides the compensation function that previously required discrete shim components.
Data Source
AI summary
A frame of a dock leveler that positions a deck portion of the dock leveler so that the deck portion is level with a surrounding dock floor at a driveway end when mounted in a pit in the dock floor includes a pit supported portion placed on a floor of the pit, a deck supporting portion providing support to the deck portion, and an adjusting assembly connected to the pit supported portion and to the deck supporting portion and operable to move and hold the deck supporting portion so that the deck portion of the dock leveler is at a selected position with respect to the surrounding dock floor.