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Modernized 6 and 10-ton Dock Levelers

Nilsson, Viola LU and Karlsson, Rebecka (2021) MMKM10 20211
Product Development
Abstract
This Master Thesis is made in collaboration with ASSA ABLOY Entrance Systems and addresses the issues and problem areas of two dock leveler models; 60 kN and 100 kN to find a new improved design. After the following product development process, a new concept was created which could withstand applied forces exceedingly.

The main purpose and goal of the project was to find a dock leveler design which could be produced with fewer components, a lower weight and made with more modern manufacturing techniques, all while meeting specific standards for dock levelers.
The project started with a literature study of safety standards, product data sheets, as well as a various FEM-analyses of current dock levelers. This pre-study served as the... (More)
This Master Thesis is made in collaboration with ASSA ABLOY Entrance Systems and addresses the issues and problem areas of two dock leveler models; 60 kN and 100 kN to find a new improved design. After the following product development process, a new concept was created which could withstand applied forces exceedingly.

The main purpose and goal of the project was to find a dock leveler design which could be produced with fewer components, a lower weight and made with more modern manufacturing techniques, all while meeting specific standards for dock levelers.
The project started with a literature study of safety standards, product data sheets, as well as a various FEM-analyses of current dock levelers. This pre-study served as the basis for the following stages of concept generation, concept selection, testing, conclusion, and discussion.

Ulrich and Eppinger’s model for product development was the main method used. Some adjustments were made to fit the project. Testing and verification of the final concept was performed with a number of FEM-simulations for different load cases.

Conclusions identified from the project were the areas of high stress and thereby areas needing improvement. The several FEM-analyses conducted gives a good representation of stresses in different load cases but should be supplemented with physical tests. The final design was constructed mainly of folded sheet metal and rectangular pipes with the assembling methods being welding and bolted joints. Overall, the new concept has fewer parts, less weld usage, uses modern manufacturing techniques, and a more robust cylinder design. (Less)
Popular Abstract
The next generation of dock levelers
With the global trade expansion, the need for modern systems to deliver goods are growing at high speed. A vital part of the expansion are dock levelers – bridging the gap between lorries carrying cargo and warehouses, ensuring a safe passage of goods.
With the project we have worked with the amazing and often forgotten product dock levelers, and we can proudly present the work resulting in a new generation of modernized dock levelers for ASSA ABLOY. The new concept has many advantages compared to its predecessors. Importantly, it has less components and a slimmer design - meaning it is more cost-efficient and environmentally friendly. The new dock leveler is much easier to manufacture and assemble,... (More)
The next generation of dock levelers
With the global trade expansion, the need for modern systems to deliver goods are growing at high speed. A vital part of the expansion are dock levelers – bridging the gap between lorries carrying cargo and warehouses, ensuring a safe passage of goods.
With the project we have worked with the amazing and often forgotten product dock levelers, and we can proudly present the work resulting in a new generation of modernized dock levelers for ASSA ABLOY. The new concept has many advantages compared to its predecessors. Importantly, it has less components and a slimmer design - meaning it is more cost-efficient and environmentally friendly. The new dock leveler is much easier to manufacture and assemble, all while meeting current safety standards exceedingly. Meaning - the new dock leveler is both safer for the people using it and the environment!

There is a huge need for a modernized dock leveler as the current versions have an out-dated design and inefficient manufacturing process. As ASSA ABLOY wishes to be a market leader and provide the best solutions for docking stations, there is always a need to innovate and improve older products. In addition, with the growing global trade market and the rise of internet shopping, we all need packages, products, and goods to be delivered in an efficient and green way. The safety aspect is also important, as dock levelers are big products with moving parts - the safety is always top priority. With the modernized design comes robustness and resilience to everyday wear and tear.

One of the most shocking discoveries in the whole project was how a small manufacturing detail could cause so much trouble. When welding the hydraulic cylinder attachments together in the manufacturing of the current dock leveler, the attachment could sometimes be welded on slightly tilted. An error that seems miniscule - but in reality causes severe damage and many problems when the dock leveler is in use. To solve this surprising problem, a self-centering cylinder attachment was developed. This meant that if it was welded on tilted, the dock leveler would still run perfectly!

The amazing technology of simulation was used as the method to actually study and understand the dock leveler. This technology opens up a world of possibilities to actually get very accurate results of the loads and stresses the product is experiencing when used in real life, all within minutes from a computer generated 3D model! (Less)
Please use this url to cite or link to this publication:
author
Nilsson, Viola LU and Karlsson, Rebecka
supervisor
organization
alternative title
Moderniserade 6 och 10-tons lastbryggor
course
MMKM10 20211
year
type
H2 - Master's Degree (Two Years)
subject
keywords
Dock leveler, FEM, stress, sheet metal, load case
language
English
id
9053091
date added to LUP
2021-06-14 09:46:51
date last changed
2021-06-14 09:46:51
@misc{9053091,
  abstract     = {{This Master Thesis is made in collaboration with ASSA ABLOY Entrance Systems and addresses the issues and problem areas of two dock leveler models; 60 kN and 100 kN to find a new improved design. After the following product development process, a new concept was created which could withstand applied forces exceedingly.

The main purpose and goal of the project was to find a dock leveler design which could be produced with fewer components, a lower weight and made with more modern manufacturing techniques, all while meeting specific standards for dock levelers.
The project started with a literature study of safety standards, product data sheets, as well as a various FEM-analyses of current dock levelers. This pre-study served as the basis for the following stages of concept generation, concept selection, testing, conclusion, and discussion.

Ulrich and Eppinger’s model for product development was the main method used. Some adjustments were made to fit the project. Testing and verification of the final concept was performed with a number of FEM-simulations for different load cases.

Conclusions identified from the project were the areas of high stress and thereby areas needing improvement. The several FEM-analyses conducted gives a good representation of stresses in different load cases but should be supplemented with physical tests. The final design was constructed mainly of folded sheet metal and rectangular pipes with the assembling methods being welding and bolted joints. Overall, the new concept has fewer parts, less weld usage, uses modern manufacturing techniques, and a more robust cylinder design.}},
  author       = {{Nilsson, Viola and Karlsson, Rebecka}},
  language     = {{eng}},
  note         = {{Student Paper}},
  title        = {{Modernized 6 and 10-ton Dock Levelers}},
  year         = {{2021}},
}