Modernized 6 and 10-ton Dock Levelers

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.