Single Side Truss Stacker Reducing Yard Footprint
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Solution Overview
Problem
Conventional truss stacking methods require significant space for land vehicles, making it impractical to stack on both sides of a process line, and often rely on hydraulics or scissor jacks, which are inefficient and prone to issues in cold climates.
Innovation Solution
A single side truss stacking system utilizing a roller conveyor with generously spaced rollers, powered by electric motors, allowing for efficient manual operation and minimizing space requirements, while avoiding hydraulics and scissor jacks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If truss stacking is performed on both sides of the process line, then stacking capacity is doubled, but the work yard size must be doubled to accommodate land vehicles
Solution Approach 1:
The patent transitions from bilateral stacking (both sides of conveyor) to unilateral stacking (single side), repositioning the stacking operation to utilize vertical space and single-side horizontal space more efficiently. The stacking stations are positioned along one side of the conveyor belt, eliminating the need for symmetric dual-side operations and reducing overall yard footprint.
Solution Approach 2:
The patent extracts and eliminates the need for land vehicles (fork trucks, semi-tractors, flat bed trailers) from the stacking operation. By implementing automated stacking stations that directly receive trusses from the conveyor, the system removes the intermediate transport step, thereby eliminating the substantial space requirements for vehicle maneuvering and positioning.
2Force
If hydraulics or scissor jacks are used for lifting, then lifting capability is achieved, but reliability decreases in cold climates and maintenance issues increase
Solution Approach 1:
The patent replaces hydraulic lifting systems and scissor jacks with an electric motor-driven chain lift mechanism. This substitution eliminates the reliability issues associated with hydraulics in cold climates (freezing, leaks, poor cold-weather performance) while providing consistent lifting capability. The electric chain drive system operates reliably across temperature extremes without the vulnerabilities of hydraulic fluid.
3Strength
If rollers are closely spaced on the conveyor, then structural integrity is maintained, but pedestrian access and manual operation become difficult
Solution Approach 1:
The patent applies different roller spacing configurations to different sections of the conveyor system. In areas where structural support is critical, rollers are closely spaced to maintain integrity. In areas where pedestrian access and manual truss handling are required, rollers are generously spaced (6 feet or more apart) to create walkable gaps. This localized variation in roller spacing allows the system to simultaneously satisfy both structural and operational requirements.
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
The system reduces the overall size of the work yard by half, enables comfortable pedestrian traffic, and maintains efficiency in both hot and cold weather, with fewer wear points and no hydraulic leaks or tripping hazards, allowing continuous operation even if individual stations fail.
Implementation Method 1
The power needs are met by electric power supply to electrodynamic appliances that power such drive trains
Implementation Method 2
a roller conveyor with generously spaced rollers
Data Source
AI summary
A truss stacking system has a main conveyor for conveying trusses of a plurality of diverse designs out of a production facility and into a stack building yard or warehouse. The main conveyor is attended by a dedicated truss stacking station for each of the diverse designs, and which station includes a truss lift sub-station and a stack-forming sub-station. Each truss lift sub-station has at least a pair of traveling masts that each raises and lowers at least one bunk (eg., fork). The bunks are raised to lift a selected truss off the outflow conveyor, the masts are driven on an outbound journey to support the lifted bunk in the airspace above the stack-forming station, and then the bunks are lowered to rest the truss on the stack. Stop posts assist in stripping the truss off the bunks.