Telescoping Lip Dock Leveler for End Loading
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Solution Overview
Problem
Conventional vertically stored dock levelers face inefficiencies and safety concerns during end loading, as the hinged lip requires additional steps to be raised and lowered, leading to increased maintenance, potential damage to trailers, and safety hazards due to an exposed gap between the trailer bed and dock floor, along with complex control systems and prone-to-malfunction limit switches.
Innovation Solution
A vertically stored dock leveler with a telescoping lip that is selectively extended and retracted using an electro-hydraulic control system, guided by a deck frame carriage, allowing for partial extension to facilitate end loading and automatic positioning to prevent damage and ensure safe operation, with sensors and simplified control wiring to prevent malfunctions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the lip is fully extended to bridge the gap between dock floor and trailer bed, then loading efficiency is improved, but the lip cannot be retracted for storage and causes safety hazards
Solution Approach 1:
The lip is made dynamically adjustable through a telescoping mechanism that allows it to extend fully during loading operations and retract to a safe position during storage. The lip can be positioned at multiple extensions (first, second, and third positions) depending on operational needs, enabling it to adapt between bridging the gap and retracting for safety.
Solution Approach 2:
The lip is divided into multiple segments that can telescope relative to each other. The lip includes a first portion, second portion, and third portion that can be positioned at different extensions, allowing the structure to be segmented and adjusted to different lengths based on whether it needs to bridge the gap or retract for storage.
2Adaptability or versatility
If the deck is raised and lowered multiple times to maneuver the lip for end loading, then the lip can be positioned to end load, but wear and tear on the leveler increases
Solution Approach 1:
The telescoping lip mechanism allows the lip to be extended and retracted without requiring the entire deck to be raised and lowered. This dynamic adjustment of the lip position reduces the frequency of deck movements and minimizes wear on the leveler structure while maintaining end loading capability.
Solution Approach 2:
The lip extension and retraction function is extracted from the deck movement mechanism. Instead of moving the entire deck to position the lip, the lip itself is made independently movable through the telescoping mechanism, separating the lip positioning function from the deck positioning function and reducing overall system wear.
3Productivity
If the lip is extended fully to bridge the gap, then cargo can be loaded, but the exposed gap remains a safety hazard
Solution Approach 1:
The lip is made dynamically adjustable through a telescoping mechanism that allows it to extend fully during loading operations and retract to a safe position during storage. The lip can be positioned at multiple extensions (first, second, and third positions) depending on operational needs, enabling it to adapt between bridging the gap and retracting for safety.
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
Enhances loading dock efficiency by minimizing unnecessary deck movements, reducing wear and tear, ensuring safety by bridging the gap between the trailer and dock, and simplifying control wiring to prevent operational errors and malfunctions.
Implementation Method 1
A vertically stored dock leveler with a telescoping lip that is selectively extended and retracted using an electro-hydraulic control system
Data Source
AI summary
The present invention is a vertically stored dock leveler with a telescoping lip that selectively extends and retracts through a range positions relative to the deck. The lip is held and guided by a deck frame carriage. When the deck is raised and lowered, the lip is extended and retracted by an electro-hydraulic control system. When the deck reaches a preselected incline position, the lip is fully extended. Sensors on the underside of the deck determine the incline position of the deck and when the lip is retracted. The leveler is then lowered until the lip engages and rests on the bed of the trailer. Similarly, when the deck is raised for storage and reaches the preselected incline position, the lip is fully retracted prior to returning to its stored position. The telescoping lip is selectively moveable to a range of partially extended position to facilitate end loading a trailer.