Spring Assist Assembly for Dock Leveler Lip Plate
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Solution Overview
Problem
Dock levelers face challenges in efficiently transitioning between raised and lowered positions due to inadequate biasing mechanisms, which can lead to damage and require significant manual force, especially when replacing hydraulic or powered systems.
Innovation Solution
A spring assist assembly with adjustable base and compression ends of springs operating along calibrating posts provides a sequenced engagement and biasing force, ensuring a consistent upward rotational force for the lip plate, allowing smooth operation and reduced manual effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional hydraulic or powered systems are replaced with simpler biasing mechanisms, then device complexity is reduced, but the ability to provide sufficient biasing force deteriorates
Solution Approach 1:
The biasing mechanism is segmented into multiple springs (typically three springs) arranged in a triangular configuration, each spring providing a portion of the total biasing force. This segmentation allows the system to achieve sufficient total force while using simpler, smaller individual springs that can be manually operated, thereby reducing overall system complexity while maintaining adequate biasing capability.
2Device complexity
If a single spring is used to bias the lip plate, then device complexity is reduced, but the ability to provide consistent force throughout the rotational path deteriorates
Solution Approach 1:
The single spring function is segmented into multiple springs distributed around the rotational path of the lip plate. Each spring engages at a different position and provides force during a specific portion of the rotation. This segmentation ensures that at least one spring is always actively providing biasing force throughout the entire rotational path, maintaining consistent force while keeping each individual spring simple.
Solution Approach 2:
The multiple springs engage and disengage in a periodic sequence as the lip plate rotates, with each spring becoming active at a specific angular position and remaining active until it disengages. This periodic engagement pattern ensures continuous biasing force throughout the rotation, with the force contribution transitioning smoothly from one spring to the next, maintaining consistent overall force while using simple individual spring components.
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 spring assist assembly enables efficient and consistent operation of dock levelers by providing a minimal overcoming force for users, effectively counteracting the weight of the lip plate, thus reducing manual effort and potential damage, and can replace traditional powered systems.
Implementation Method 1
A spring assist assembly extends between the deck and the lip plate. The spring assist assembly includes a plurality of springs that linearly operate along respective calibrating posts to bias the lip plate toward the raised position.
Implementation Method 2
These biasing mechanisms serve to allow for convenient lifting of the dock leveler from a lowered position to a raised position. These biasing mechanisms also provide for a smooth return rotation from the raised position to the lowered position
Data Source
AI summary
A dock leveler includes a lip plate that is rotationally attached to an edge of a deck at a hinge and operable between raised and lowered positions. A spring assist assembly extends between the deck and the lip plate. The spring assist assembly includes a plurality of springs that linearly operate along respective calibrating posts to bias the lip plate toward the raised position. A base end and a compression end of each spring are adjustable along the respective calibrating posts.