EGM 2169 F1

Design of a Pallet Lifter

Prepared by, Lim Kim Lean (J07003341)

Pallet Standardization
Recommended Pallet Size
4-way entry, 1000mm x 1200mm pallet is the recommended standard for the grocery and fast-moving consumer goods industry. The standard pallet shall have a safe working load of minimum one tonne. RECOMMENDED PALLET 1200mm x 1000mm 4-way entry pallet is in accordance with the ISO6780 specification. Nominal Dimension of pallet (L or W) Entries and openings L1 and W1 max. 1000 1200 Dimensions in millimeters 150 150 L2 and W2 min. 720 770

Why 1000mm x 1200mm pallet?

Compatible with standard ocean going containers and the majority of trucks Dominant size used in Asia (China, Hong Kong, Thailand, Malaysia, Indonesia, Philippines and

Singapore)
Endorsed by ECR Asia Conform to International Standard - ISO 6780 'General-purpose flat pallets for through transit

of goods - Principal dimensions and tolerances'

Conform to Singapore Standard - SS 334 'Specification for Timber Pallets' Major retailers in Singapore have already adopted this standard Sufficiently wide for drive in racking.

Benefits of Pallet Standardization Standardization of pallets provides the platform for pallet exchange. In the ideal scenario, goods can be transported from the manufacturer, through the distributor, to the retail store on the same pallet. By eliminating the need for manual transfer of goods to another pallet, productivity and work efficiency are improved. The reduction in both labour and handling of goods will reduce delivery and transfer costs. Standardization of pallet sizes will in turn allow standardization of palletisers, racking and warehouse design. This will result in economy of space and facilitate automation. Other benefits include the following:
Reduction in multiple handling Reduction of damaged goods losses through minimal manual handling Reduction in number of transportation trips Minimization of the wastage of pallets Elimination of the need for sorting of pallets Reduction of unloading time for suppliers Reduction in warehouse storage cost Facilitates the concept of shared assets Facilitates regional trade and pallet pooling activities

ISO Standard Pallets (ISO 6780: Flat pallets for intercontinental materials handling) * ISO 48" x 40" - Primarily used in North America * ISO 1200mm x 1000mm - Primarily used in Europe and Asia * ISO 1140mm x 1140mm - Primarily used in Australia * ISO 42" x 42" - Worldwide use * ISO 1100mm x 1100mm - Primarily used in central Asia * ISO 1200mm x 800mm - A pallet specifically designed for European use to fit through standard doorways. North American Pallets * Grocery Manufacturers' Association (GMA) 48"x40" * 42"x42" - Primarily used for communications equipment and paint. * 48"x48" - Primarily used for drums * 40"x48" - Primarily used for military and cement shipments * 44"x44" - Primarily used to handle chemical drums * 36"x36" - Primarily used in the beverage industry * 48"x36" - Primarily used for Shingle Manufacturers Australian Standard Pallet 1165mm x 1165mm - The Australian Standard Pallet is a pallet size commonly found in Australia but found rarely elsewhere. It is a square hardwood pallet which fits perfectly in the RACE container of the Australian Railway, but is ill suited to fitting in the standard ISO containers used around the globe.

Examples of various types of wooden Pallets (UK sizes)

In many situations, recycled or reconditioned pallets are the natural choice. Some of the benefits of using recycled pallets are:

y y y y

New pallets attract packaging waste and have cost implications to customer. Reconditioned pallets don't. Used pallets are exempt from the packaging waste regulations - so there is less administration and paperwork for you Recycled pallets are a cheaper, often more readily available option Reconditioned pallets may often be stronger than new ones (providing they are repaired to their original specification). Recent USA research showed that the average used pallet is 13% stronger than new, because air drying (seasoning) during usage increases the wood strength.

Pallet Ref

Size, mm

Weight, kg

Loading Capacity, Kg

Comments

UK1: 4 way Grade 1 pallet Short board pallet 1000 1500

1000x1200 15 - 25

Top grade standard pallet. Heavy duty. Often used in food industry (customers can specify a "no glass" pallet) & packaging industry.

UK2: 4 way grade 2 pallet Long board pallet 750 1250

1000x1200 15 - 25

Grade 2 pallet. Heavy duty. Often used in manufacturing industry & packaging industry.

UK3: 1000x1200 15 - 25 4 way legger pallet 750 1000

Heavy duty pallet mainly used in the plastics industry.

UK3: Winged Convert 1000x1200

Heavy duty pallet, the wings facilitate the use of shrinkwrap. Also available as a flush sided convert.

UK3: 4-way PB Pallet (fruit pallet) 1000x1200

This mid weight pallet originates from the fruit industry, and a number of other applications.

UK3: Flush sided Convert pallet also known as a strapper pallet 1000x1200 Mid weight pallet. Used in packaging & distribution, & retail industry.

UK3 VMF:

1000x1200

Perimeter based pallet (Heavy duty) originating from France. Often used in the glass industry.

UK4: Light Weight pallet, also available as a 3-legger pallet 1000x1200 10 - 18 500 - 750

Mainly used in the packaging industry, often supplied to retail.

UK5: Fully reversible 2 way pallet 1000x1200 15 - 25 750 1500

A heavy duty pallet that is mainly used in the building industry.

Pallet Lifter
Before designing the pallet lifter, there are few considerations that must be made. These considerations are the strength of the material, the factor of safety, the allowable tensile and shear stresses, dimensions of the bars and the availability of the bars in the market, modes of failures and lastly the cost effectiveness. Strength of material The strength of a material is its ability to withstand an applied stress without failure. Yield strength refers to the point on the engineering stress-strain curve beyond which the material begins deformation that cannot be reversed upon removal of the loading. The applied stress may be tensile, compressive, or shear. Strength is considered in terms of compressive strength, tensile strength, and shear strength, namely the limit states of compressive stress, tensile stress and shear stress, respectively. The effect of dynamic loading is probably the most important practical part of the strength of materials, especially the problem of fatigue. Repeated loading often initiates brittle cracks, which grow slowly until failure occurs. However, the term strength of materials most often refers to various methods of calculating stresses in structural members, such as beams, columns and shafts. The methods that can be employed to predict the response of a structure under loading and its susceptibility to various failure modes may take into account various properties of the materials other than material (yield or ultimate) strength. For example failure in buckling is dependent on material stiffness.

Uniaxial stress is expressed by: where F is the force [N] acting on an area A [m2]. The area can be the undeformed area or the deformed area, depending on whether engineering stress or true stress is used. Yield stress is the lowest stress that gives permanent deformation in a material. Tensile stress is the stress state caused by an applied load that tends to elongate the material in the axis of the applied load. The strength of structures of equal cross sectional area loaded in tension is independent of cross section geometry. Materials loaded in tension are susceptible to stress concentrations such as material defects or abrupt changes in geometry. Shear stress is the stress state caused by a pair of opposing forces acting along parallel lines of action through the material. Factor of safety is a design constraint that an engineered component or structure must achieve. The actor of safety is determined by the designer to obtain the allowable stresses of the component.

Pallet Lifter Design

Factor of safety: 4 Beam dimensions: (1&2)=75x100x640mm, (3)=65x65x1500mm Beam thickness: 10mm Beam weight: (1&2)=15.331kg, (3)=25.905kg Shackle mounts dimensions: 60x60x40mm, outside 60mm, inside 36mm Locking pin dimensions: 19mmX100mm Total weight: 1910.74kg = 18744.3N Pallet weight: approx. 25kg Maximum loading capacity: 1800kg (based on calculation) Yield strength for: ASTM A500 = 315MPa, ASTM A36 = 250MPa Allowable tensile stress, allow: ASTM A500:- 315M/4 = 78.75MPa ASTM A36 :- 250M/4 = 62.50MPa Allowable shear stress, allow: ASTM A500:- 315M/8 = 39.375MPa ASTM A36 :- 250M/8 = 31.250MPa

No. Parts Material 1 Main Support Beam ASTM A500 (Mild Carbon Steel) 2 Adjustable Support Beam ASTM A500 (Mild Carbon Steel) 3 Pallet Support Beam ASTM A500 (Mild Carbon Steel) 4 Shackle Mount ASTM A36 (Steel Alloy) 5 Locking Pin ASTM A36 (Steel Alloy) *Locking pin is connected to the adjustable support beam by a chain.

Quantity 1 1 2 4 2

Component:1. Main Support Beam Failure mode:- Shearing failure of the bar at contact point - Tensile failure of the welded joints - Shearing failure of the welded joints Area = 0.013m x 0.02m + 0.055m x 0.01m = 8.1 x 10-4m2 Allowable force, Fallow = 78.75M x 8.1x10-4 = 63787.5N Welded joints Butt joint F =txlx Fallow = 0.005 x 0.065 x 39.375M = 12796.875N x 4 (for single bar)

Transverse fillet joint F = A x = 0.707sl x Fallow = 0.707(0.01)(0.065)(78.75M) = 36189.56N x 4 (for single bar)

3. Pallet Support Beam Failure mode:- Tensile failure of the beam at pin inserts Area = 0.045m x 0.02m + 0.045m x 0.02m = 1.8 x 10-3m2 Allowable force, Fallow = 78.75M x 1.8x10-3 = 141750N - Deflection of beam Ix = (0.065)4 (0.045)4 = 1.146x10-6m4 = ,M= , =

78.75M = W = 9256.15N (for single bar) Maximum loading 1800kg = = 2.81x10-3m

max

4. Shackle mount Failure modes:- Tensile failure of the part - Shearing failure of the part - Tensile failure of the welded joint Area = 0.024 x 0.04 = 9.6x10-4m2 For tensile stress, Fallow = 9.6x10-4 x 62.5Mpa = 60000N For shear stress, Fallow = 9.6x10-4 x 31.25Mpa = 30000N Welded joints For vertical weld (L=0.06) Fallow = 0.707(0.005)(0.06)(78.75M) = 16702.875N (tensile) For horizontal weld (L=0.04) Fallow = 0.707(0.005)(0.04)(78.75M) = 11135.25N (tensile)

Fallow = 0.707(0.005)(0.06)(39.375M) = 8351.44N (shear) Fallow = 0.707(0.005)(0.04)(39.375) = 5567.625N (shear)

Total allowable tensile force = 55676.25N (on single mount) Total allowable shear force = 27838.13N (on single mount) 5. Locking pin Failure mode:- Shearing of the pin at contact point Area = (0.009)2 = 2.54x10-4m2 Fallow = (31.25M)(2.54x10-4) = 7952.16N (on one side) Total allowable force on one pin = 15904.32N Two pins can support 31808.64N

Attachments

Jaw Inside Width W 18 20 22 25 28 32 34 40 45 50 56 63 70 80 90 100 107 117 130 140 153

Inside Length S=2.2 W 40 44 49 55 62 70 79 88 99 110 124 139 154 176 198 220 236 258 286 308 337

BDY Pin EYE Material Diameter Outside Diameter D Diameter d 10 12 14 16 17 19 22 24 27 30 34 38 43 48 54 60 66 71 79 84 93 12 14 16 19 20 22 26 28 31 35 39 44 50 55 62 69 76 82 91 97 110 24 28 32 38 40 44 52 56 62 70 78 88 100 110 124 138 152 164 182 184 220 -

Safe Working Load (Tonnes) Grade 30 1.0 1.25 1.6 2.0 2.5 3.2 4.0 5.0 6.3 8.0 10.0 12.5 16.0 20.0 25.0 32.0 40.0 50.0 63.0 80.0 Grade 40 Grade 63 1.0 1.25 1.6 2.0 2.5 3.2 4.0 5.0 6.3 8.0 10.0 12.5 16.0 20.0 25.0 32.0 40.0 50.0 63.0 80.0 2.0 3.25 4.75 6.5 8.5 9.5 12.0 13.5 17.0 25.0 35.0 42.0 50.0 65.0 83.0 100.0 Grade 80

1.0 1.25 1.6 2.0 2.5 3.2 4.0 5.0 6.3 8.0 10.0 12.5 16.0 20.0 25.0 32.0 40.0 50.0 63.0

The highlighted region is the dimensions for the D-shackle that will be used together with the pallet lifter as shown in the picture. The grade C D-shackle is chosen to be used with the pallet lifter.

Malaysian Market

Product Description FOR SALE WITHIN MALAYSIA ONLY. ASTM A-500 MILD STEEL SQUARE HOLLOW SECTIONS (SHS) 20MMX20MM..30X30..32X32..35X35..38X38..40X40..50X50..60X60.. 65X65..75X75..80X80..90X90..100X100..120X120..125X125..150X150. .180X180..200X200..250X250..300X300..350MM X 350MM. ASTM A-500 MILD STEEL RECTANGULAR HOLLOW SECTIONS (RHS) 38MMX19MM..38X25..50X25..65X35..65X38..75X25..75X38..75X50.. 100X50..100X75..120X60..120X80..125X50..125X75..150X50..150X75.. 150X100..160X80..200X100..200X150..250X150..300X200..400X200.. 400mm X 300mm..

References: http://www.cwhsb10.com/sdp/900713/4/pd-4573542/53452451868747/SQUARE_AND_RECTANGULAR_HOLLOW_SECTIONS.html http://www.liftarts.com/DShackles.html http://www.whirlowdale.com/UK-reconditioned-pallets.aspx http://en.wikipedia.org/wiki/ASTM_A500 http://en.wikipedia.org/wiki/ASTM_A36 http://en.wikipedia.org/wiki/Strength_of_materials www.gs1hk.org/files/gs1/document/Pallet%20Standardisation.pdf