Trailer Push Bar System for Controlled Pallet Unloading
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Solution Overview
Problem
The existing methods for unloading cargo, particularly palletized cargo, from trailers are inefficient due to high friction issues with traditional tilting trailers, leading to uncontrolled sliding and potential damage, and often require additional unloading equipment that is not always available or economical.
Innovation Solution
A tilting flatbed trailer system equipped with push bars secured between chains, a motor-driven chain system, and a hydraulic lift actuator, allowing controlled tilting and movement of pallets with ground extensions to prevent rapid descent and facilitate safe unloading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a traditional tilting trailer is used to unload palletized cargo, then the trailer can be tilted to allow gravity to move pallets off, but the friction between the pallet and trailer bed is so great that it is difficult to tilt the trailer sufficiently to overcome the friction
Solution Approach 1:
A push bar is introduced as an intermediary mechanical element between the chain system and the pallet. The push bar translates the chain's linear motion into a pushing force that directly acts on the pallet, overcoming the friction between the pallet and trailer bed without requiring extreme tilting angles.
Solution Approach 2:
The system replaces the traditional gravity-dependent tilting mechanism with a chain-driven push bar system. Instead of relying solely on gravitational force from steep tilting, the mechanical chain system provides controlled pushing force to move the pallet, substituting mechanical actuation for gravity-based operation.
2Productivity
If the trailer is tilted sufficiently for a pallet to begin sliding, then the pallet can be moved off the trailer, but it is difficult or impossible to control the speed at which the pallet slides down
Solution Approach 1:
The operator can control the chain system to provide continuous or intermittent pushing force, effectively regulating the pallet's movement speed. The system responds to operator input by adjusting the push bar's motion, maintaining controlled descent rather than uncontrolled sliding.
Solution Approach 2:
The system transitions from a static tilting angle approach to a dynamic control mechanism. The chain system can adjust its motion in real-time, providing variable pushing force to control the pallet's speed throughout the unloading process, adapting to different stages of movement.
3Adaptability or versatility
If a forklift is carried on the truck/trailer to enable unloading, then unloading equipment is available at the delivery site, but the size and weight of the transportation setup increases
Solution Approach 1:
The trailer bed serves multiple functions: it transports the pallet during transit and then transforms into an active unloading mechanism through the chain and push bar system. This eliminates the need for separate unloading equipment like forklifts, as the trailer itself becomes the unloading device.
Solution Approach 2:
The unloading function is extracted from separate equipment (forklift) and integrated directly into the trailer structure through the chain and push bar system. This eliminates the need to transport additional unloading equipment, reducing total weight while maintaining unloading capability.
4Adaptability or versatility
If a huge flatbed semi-trailer is used to transport only 1-4 pallets, then unloading equipment can be transported to the delivery site, but the trailer size is inefficiently large
Solution Approach 1:
The trailer bed serves multiple functions: it transports the pallet during transit and then transforms into an active unloading mechanism through the chain and push bar system. This eliminates the need for separate unloading equipment like forklifts, as the trailer itself becomes the unloading device.
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
Enables efficient and controlled unloading of palletized cargo by reducing friction and preventing damage, eliminating the need for additional unloading equipment, and allowing for flexible positioning of pallets during loading and unloading.
Implementation Method 1
a hydraulic lift actuator, allowing controlled tilting and movement of pallets
Implementation Method 2
a motor-driven chain system, and a hydraulic lift actuator, allowing controlled tilting and movement of pallets
Implementation Method 3
it is difficult to tilt the trailer sufficiently to overcome the friction so that the pallet slides off the tilted trailer under the force of gravity
Data Source
AI summary
A Trailer Loading/Unloading System may comprise a tilting flatbed trailer having one or more push bars configured to move along the surface of the trailer bed push palletized cargo off the trailer, move palletized cargo back and forth on the trailer, and prevent rapid descent or undesirable slipping of palletized cargo. Each of the push bars may be secured between a chain on the left side of the trailer bed and a chain on the right side of the trailer bed. These two chains may loop around a rear guide shaft at the rear of the trail and a front guide bar shaft at the front of the trailer. The guide shafts may be secured beneath the surface of the trailer, and may include sprockets around which the chains loop. A motor, e.g., a winch, may be secured to the trailer and may drive, using a sprocket and chain running around a shaft protruding from the motor, one of the guide shafts, e.g., the front shaft, by turning a sprocket mechanically secured to the front guide shaft. The Trailer Loading/Unloading System may further comprise a hydraulic lift actuator for raising the front of the trailer, thereby tilting the trailer. Palletized cargo may be unloaded from the trailer by raising the front of the trailer and thereby tilting the trailer, actuating the motor to push palletized cargo toward the rear of the trailer, and pulling the trailer forward when the edge of the palletized cargo is touching the ground.