Support Module for Pallet Stability on Roll Conveyors
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Solution Overview
Problem
Existing slave pallet designs are incompatible with roll conveyors, leading to risks of damage and toppling, and they often deflect excessively due to mass distribution issues, increasing the risk of operator injury and product damage.
Innovation Solution
A support module with a body defining an opening for a pallet support and a lower surface to abut a platform's top deck, providing stability, alignment, and flexibility in pallet size, which can be retrofitted to existing platforms without redesign, and features projections for secure positioning and attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If existing slave pallet designs are used, then pallet stacking is enabled, but stability is reduced and toppling risk increases
Solution Approach 1:
The support module divides the slave pallet structure into modular components: a platform body and separate support modules that can be independently positioned. Each support module contains an opening that receives a pallet support, creating discrete stabilization points rather than a continuous unsupported surface. This segmentation allows precise control over load distribution and stacking stability.
2Stability of the object's composition
If existing slave pallet designs are used, then pallet stacking is enabled, but deflection increases due to mass distribution issues
Solution Approach 1:
The support module implements local quality by concentrating structural reinforcement at specific locations where pallet supports are received. The opening in the support module body is positioned to align with pallet support locations, creating localized stiffening zones. This allows the platform to maintain flexibility where needed while providing targeted rigidity at load-bearing points, reducing overall deflection without requiring uniform mass distribution throughout the entire platform.
3Device complexity
If pallet supports are feet, then pallet structure is simple, but they become trapped between rollers and risk damage
Solution Approach 1:
The support module body acts as an intermediary between the pallet support (foot or wheel) and the roll conveyor rollers. Instead of allowing direct contact between the pallet support and rollers, the opening in the support module body provides a controlled interface that guides the pallet support past the rollers. This intermediary structure prevents entrapment while maintaining compatibility with both foot and wheel support types.
4Ease of operation
If wheels are used as pallet supports, then mobility is improved, but they become jammed between rollers
Solution Approach 1:
The support module body serves as a mediator that allows wheeled pallets to pass over roll conveyors without the wheels becoming jammed. The opening in the support module is sized and shaped to guide the wheel through the roller gap, preventing the wheel from becoming trapped between rollers while preserving the wheel's rolling function on flat surfaces.
5Stability of the object's composition
If support modules are added to platforms, then stability and alignment are improved, but device complexity increases
Solution Approach 1:
The support module is designed to be nested within or attached to the platform structure. The support module body contains an opening that receives the pallet support, and the entire assembly integrates with the platform without requiring completely separate structures. This nesting approach adds functionality while minimizing the increase in overall device complexity.
6Stability of the object's composition
If existing slave pallets are used, then pallet stacking is enabled, but alignment errors lead to excessive deflection and toppling
Solution Approach 1:
The support module performs preliminary alignment action by providing a pre-positioned opening that guides the pallet support into the correct location before the pallet is fully placed on the platform. This preliminary guidance structure compensates for alignment errors, ensuring that even if the pallet is not perfectly positioned, the support module's opening will guide it to the correct alignment, preventing excessive deflection and toppling.
Data Source
AI summary
A platform including a top deck is configured to receive a pallet when stacked thereon. The top deck includes at least one integrally formed recessed support configured to receive a pallet support of the pallet. The at least one recessed support includes a perimeter recessed in the top deck and which defines a cavity configured to receive the pallet support.