Trailer Bearer Beam Tracks for Double-Deck Pallet Loading
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Solution Overview
Problem
Existing systems for providing additional support levels in enclosed storage spaces, such as trucks and warehouses, face challenges including the need for forklift access, increased weight, labor-intensive assembly and disassembly, and safety hazards due to protruding tracks, which limit their efficiency and versatility.
Innovation Solution
A bearer system with enclosed tracks that allow movable bearer supports to be moved horizontally, attached to a vertical structure, providing adjustable support without the need for forklift access and reducing weight and labor, while minimizing protrusion into the storage space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a removable second floor is installed to double storage capacity, then storage volume is improved, but the system requires forklift access and becomes difficult to operate when loading bays are unavailable
Solution Approach 1:
The patent replaces the forklift-based mechanical lifting system with a gravity-based roller conveyor system. Loads are pushed onto rollers at the loading bay, and gravity automatically transports them along the rollers to their storage positions, eliminating the need for forklifts to access the interior of the vehicle for loading and unloading operations.
Solution Approach 2:
The roller conveyor system is self-powered by gravity, requiring no external power source or active mechanical intervention. Loads simply need to be placed on the rollers at the loading end, and the system automatically performs the transport function without requiring forklifts or additional energy input.
2Volume of moving object
If movable bearer supports with tracks are used to provide additional support levels, then storage capacity is improved, but the tracks protrude into the storage space creating safety hazards and obstructing space
Solution Approach 1:
The roller conveyor system is nested within the existing vehicle structure, with rollers mounted along the sides and top of the cargo area. The rollers are positioned to utilize the available space without protruding into the cargo volume, effectively hiding the support mechanism within the overall structure while maintaining full storage capacity.
Solution Approach 2:
The patent transitions from horizontal track systems that protrude into the cargo space to a three-dimensional roller arrangement that utilizes the vertical and lateral dimensions of the vehicle structure. Rollers are mounted along the sides and top, creating a gravity-fed conveyor system that operates in multiple dimensions without obstructing the cargo area.
3Area of stationary object
If bearers are removed and stored when not in use, then storage space is maximized, but labor time and complexity increase
Solution Approach 1:
The roller conveyor system serves multiple functions: it provides structural support for the vehicle, creates the second loading bay, and enables gravity-based material handling. This multi-functional design eliminates the need to remove or store components, as the system remains in place and provides continuous utility.
Solution Approach 2:
The roller conveyor system is pre-installed as a permanent fixture during vehicle manufacturing, eliminating the need for assembly and disassembly operations. The system is ready for immediate use upon vehicle delivery, requiring no preparatory actions by the user.
4Volume of moving object
If the second floor is lowered and locked into position for storage, then storage capacity is doubled, but the system increases tare weight of the vehicle
Solution Approach 1:
The patent uses thin-walled roller supports and conveyor components that provide the necessary structural function with minimal material. The rollers and support structures are designed to be lightweight yet sufficient for their load-bearing function, reducing the overall weight addition to the vehicle.
Solution Approach 2:
The system uses lightweight materials and optimized structural parameters for the roller supports and conveyor components. By changing the material parameters and structural dimensions to the minimum required for functionality, the tare weight increase is minimized while maintaining the doubled storage capacity.
Data Source
AI summary
A system for optimising storage in an enclosed transport trailer (6), having transverse bearing beams (2) for supportin a load such as loaded pallets (12, 13) at a mid height of the trailer such that two storage levels are available. The beams have a wheel (10) at each end that runs in a horizontal track (11) attached to each side wall of the trailer, the track enclosing the wheels to prevent them from disengaging from the track. Adjacent beams can be attached togethe at variable spacings using a spacer bar (15) to suit a particular pallet or load size. The track has a junction adjacent th open end (20) of the trailer that leads up to another track (18) immediately below the roof line where the beams can b moved to an out of the way storage position (19) when not required.