Pallet with integrated weighing function

Abstract

The present invention relates to a pallet, or like platform, for supporting a load to be lifted or lowered, comprising: a deck having a deck upper surface for placing the load thereon, a load sensor device, comprising a weighing element included in a measuring circuit, wherein the weighing element contacts the deck over a contact area such that the weighing element deforms in unity with the deck and an electrical property of the weighing element varies with the deformation of the weighing element.

Claims

1. A pallet, or platform, for supporting a load to be lifted or lowered, comprising: a deck having a deck upper surface for placing the load thereon, a load sensor device, comprising a weighing element included in a measuring circuit, wherein, the weighing element contacts the deck over a contact area such that the weighing element deforms in unity with the deck and an electrical property of the weighing element varies with the deformation of the weighing element.

2. A pallet according to claim 1, comprising a support structure for spacing the deck from a supporting surface like a floor, wherein the weighing element is restricted between the support structure and the deck, in particular constrained with respect to movement of the weighing element transverse with respect to the deck upper surface.

3. A pallet according to claim 1, wherein the weighing element contacts the deck over the contact area through a spacing member arranged between the deck and the weighing element and/or at a deck lower surface over the contact area.

4. A pallet according to claim 1, the deck having a lower surface, wherein the weighing element contacts the deck lower surface over the contact area.

5. A pallet according to claim 2, wherein the support structure comprises at least one block for spacing the deck from the supporting surface and the weighing element is restricted between the block and the deck lower surface.

6. (canceled)

7. A pallet according to claim 5, wherein the block comprises a receptacle and the weighing element is at least partly, in particular entirely, arranged in the receptacle.

8. A pallet according to claim 7, wherein the receptacle is sized such that it extends beyond a side of the weighing element opposite the deck lower surface to facilitate deformation of the weighing element.

9. A pallet according to claim 5, wherein the weighing element comes into abutment with the block at the outer circumference of the weighing element only.

10. A pallet according to claim 1, wherein the weighing element comprises a layered structure.

11. A pallet according to claim 10, wherein the weighing element comprises a flexible layer facing the deck, wherein the flexible layer defines the contact area.

12. A pallet according to claim 10, wherein the spacing member is included in the flexible layer.

13. A pallet according to claim 10, wherein the flexible layer comprises an adhesive to secure the weighing element to the deck.

14. A pallet according to claim 13, wherein the adhesive is electrically conductive, and in particular the conductive properties change due to deformation of the flexible layer.

15. A pallet according to claim 10, wherein the weighing element comprises a pair of layers that form a cavity in between the pair of layers.

16. A pallet according to claim 10, wherein the weighing element comprises a multilayer PCB having a spacing layer that allows a neighbouring layer to deform, in particular to flex in unity with the deck.

17. A pallet according to claim 1, wherein the weighing element comprises a plurality of measurement sections, wherein in particular the plurality of measurement sections are spatially distributed over the weighing element to facilitate discrimination between different modes of deformation of the deck.

18. A pallet according to claim 1, wherein the deck upper surface for placing the load thereon is a unitary or monolithic load supporting surface.

19. A pallet according to claim 1, comprising a skid, wherein the at least one block, in particular a plurality of blocks, spaces/space the deck from the skid.

20. A pallet according to claim 1, comprising a number of weighing elements, wherein each respective weighing element is integrated in a respective block.

21. (canceled)

22. A method for manufacturing a pallet according to claim 1, comprising calibrating the load sensor device, in particular calibrating the load sensor device after integrating the load sensor device with the pallet.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The features and advantages of the invention will be appreciated upon reference to the following drawings of a number of exemplary embodiments, in which:

[0040] FIG. 1 shows a perspective view of a pallet according to the present invention;

[0041] FIG. 2 shows the pallet of FIG. 1 in exploded perspective view;

[0042] FIG. 3 shows a detail of FIG. 1 namely a block prepared to accommodate a load sensor device, comprising a weighing element;

[0043] FIG. 4a is a perspective view of another embodiment of a block of FIG. 3;

[0044] FIG. 4b is a cross sectional perspective view of the block of FIG. 4a;

[0045] FIG. 5 is a side view of a load sensor device;

[0046] FIG. 6 is a detail of another embodiment of a load sensor device in exploded perspective view;

[0047] FIG. 7 shows a detail III of the pallet of FIG. 1 in partially cut-away view;

[0048] FIG. 8 shows a schematic view of the architecture of an electronic tag for use in the invention; and

[0049] FIG. 9 shows a schematic view of a pallet logistic system according to the invention.

DETAILED DESCRIPTION OF DRAWINGS

[0050] FIG. 1 shows a perspective view of a pallet 1 according to the present invention in its ready to use state. The illustrated pallet is of conventional Euro Pallet dimensions (1200 mm800 mm144 mm). It includes a deck 10 having a deck upper surface 12 a deck lower surface 14 and a deck peripheral edge 16. When a load is placed on the deck 10, the deck 10 deforms as a unit. The deck 10 has its own specific deformation modes depending on a specific load scenario of the pallet 1.

[0051] Blocks 20 are provided beneath the deck 10 and space the deck 10 from a skid 30. The skid 30 also has a skid upper surface 32 a skid lower surface 34 and a skid peripheral edge 36. The skid 30 and blocks 20 together are also referred to as support structure. The support structure 20, 30 spaces the deck 10 from a supporting surface like a floor. When the pallet 1 carries a load, the deck 10 deforms. The central block 20e comprises electronic system 80. The deck 10 deforms as a unit.

[0052] Openings 4 between the blocks 20 allow the forks of a fork lift truck to be inserted under the deck 10 to engage the deck lower surface 14 for lifting the pallet 1 as is otherwise conventional.

[0053] The blocks 20 are provided with sleeve portions 22 that extend upwards, covering the deck peripheral edge 16 to a position level with the deck upper surface 12. The sleeve portions 22 also extend downwards and overlap the skid peripheral edge 36. Furthermore, it may be seen that the deck peripheral edge 16 and the skid peripheral edge 36 are provided with chamfers 17, 37 at the location of the openings 4. This facilitates access by a fork-lift and reduces any damage due to the fact that an impact may be deflected.

[0054] FIG. 2 shows the pallet 1 of FIG. 1 in exploded view whereby the individual elements that form the pallet 1 can be better seen. Turning first to the deck 10, it can be seen that the deck peripheral edge 16 has cutaway regions 18 at the corners and in the middle of each side. Between the cutaway regions 18 are the chamfers 17. In this embodiment, the deck peripheral edge 16 is either cutaway or chamfered around the full periphery although it will be understood that these regions may be spaced from each other.

[0055] There are in total nine blocks 20A-I, of which all except the central block 20E, comprise sleeve portions 22 and spacer portions 24. The central block 20E comprises only a spacer portion 24. The corner blocks 20A, 20C, 20G and 20I all have angled sleeve portions 22, while the side blocks 20B, 20D, 20F and 20H in the middle of each side, have straight sleeve portions 22. The sleeve portions 22 all extend above the respective spacer portion 24 by a distance that corresponds to the thickness of the deck 10 and have a width that corresponds to a depth of the cutaway regions 18. This ensures that the deck 10 can be recessed into the sleeve portions 22 with an exterior surface of the sleeve portions 22 being co-linear with the deck peripheral edge 16. The central block 20E comprises a cavity 26 in which is located an electronic system 80. The electronic system 80 includes a tag 60, shown in FIG. 4a. The tag 60 is a proprietary electronic active RFID chip-based, track and trace device with incorporated battery, capable of transmitting over ranges of up to 300 metres, available from BM Innovations GmbH under the name BlueRobin, operation of which will be described in further detail below. Other similar devices such as Bluetooth low power (BLE) devices may also be used.

[0056] The skid 30 is similar in terms of the skid peripheral edge 36, which has cutaway regions 38 at locations corresponding to the blocks 20. The parts of the skid peripheral edge that are not cut away are chamfered at chamfers 37. In the disclosed embodiment, the deck 10 is closed but it will be understood that open or apertured decks may be used as appropriate. The illustrated skid 30 is a five member skid having first, second and third skid members 30A-C and front and back braces 30D, E. The skid 30 may be of conventional wooden construction with the skid members 30A-E being glued and pegged together in conventional manner. Alternatively, the whole skid may be of MDF or the like unitary construction. In the illustrated embodiment, all of the skid members 30A-E have chamfers on all sides. It will be understood that chamfering can also be limited to just the skid peripheral edge 36.

[0057] FIG. 3 shows a detail of FIG. 1 namely a block 20E. The block 20E is prepared to accommodate an electronic system 80 shown in FIG. 5. The block 20E comprises a receptacle 72. The receptacle 72 is configured to accommodate the weighing element 87 shown in FIG. 5. The receptacle 72 is sized such that it extends beyond a side of the weighing element 87 opposite the deck lower surface 14. This facilitates deformation of the weighing element 87. The weighing element 87 comes into abutment with the block 20E. The weighing element 87 comes into abutment with the block 20E at stop flange 73. The stop flange 73 extends around the receptacle 72. The receptacle 72 extends inwards beyond the stop flange 73. The weighing element 87 contacts the stop flange 73 at the outer circumference of the weighing element 87 only. The block 20E comprises a cavity 74. The cavity extends transverse with respect to the receptacle 72.

[0058] Another embodiment of a block 20E of FIG. 3 is described referring to FIGS. 4a and 4b. FIG. 4a is a perspective view of a block 20E. FIG. 4b is a cross sectional perspective view of the block 20E of FIG. 4a. The block 20E accommodates an electronic system 80. The electronic system 80 comprises a load sensor device 71 and a tag 60. Electronic tag 60 is installed in the cavity 78 of the central block 20E and initialised. The tag 60 is battery 81 powered and designed to operate for a period of up to 10 years based on normally expected usage. The load sensor device 71 comprises a weighing element 87 as shown in FIG. 4a. The block 20E comprises a hollow 78. The block 20E has a hollow structure. The hollow 78 is formed within a profile. The profile is square. The profile has a profile wall 75. The hollow 78 is configured to accommodate the weighing element 87 shown in FIG. 5. The weighing element 87 comes into abutment with the block 20E. The weighing element 87 comes into abutment with the block 20E through two cross members 76a, 76b. The weighing element 87 contacts two cross members 76a, 76b. The two cross members 76a, 76b support the weighing element 87 in the hollow 78. The two cross members 76a, 76b divide the hollow 78. The two cross members 76a, 76b are mutually spaced. The two cross members 76a, 76b extend in parallel. A filling member 79 may be provided between the two cross members 76a, 76b. The two cross members 76a, 76b allow the weighing element 87 to deform. Therefore, the two cross members 76a, 76b engage the weighing element 87 to each make a line contact between the two cross members 76a, 76b and the weighing element 87. The weighing element 87 has a top layer 82. The top layer may directly contact the deck 10. As an alternative, or additionally, the weighing element 87 contacts the deck 10 through a spacer 77.

[0059] FIG. 5 is a side view of an electronic system 80. The electronic system 80 comprises a load sensor device 71 and an tag 60. The load sensor device 71 comprises a weighing element 87. The weighing element 87 is shown in contact with the deck 10. The weighing element 87 contacts the deck lower surface 14. The weighing element 87 comprises a layered structure 82, 83, 84, 85 as is better shown in FIG. 6. The weighing element 87 contacts the deck lower surface 14 through a flexible layer 85. The flexible layer 85 is deformable so that manufacturing tolerances can be accommodated and a defined contact area between the deck 10 and the weighing element 87 is determined by the flexible layer 85. The flexible layer 85 secures the weighing element 87 to the deck 10. The weighing element 87 contacts the deck 10 over a contact area such that the weighing element 87 deforms in unity with the deck 10 and an electrical property of the weighing element 87 varies with the deformation of the weighing element 87. As a result, at least the top layer 82 can flex in unity with the deck 10 as shown with a dash line.

[0060] The flexible layer 85 may comprises an adhesive to secure the weighing element 87 to the deck 10. As an option, the adhesive in the flexible layer 85 is electrically conductive. The conductive properties change due to deformation of the flexible layer 85.

[0061] The weighing element 87 is restricted between the support structure and the deck 10. The weighing element 87 is in particular constrained with respect to movement of the weighing element 87 transverse with respect to the deck 10. The weighing element 87 is restricted between the block 20E of e.g. FIG. 4a and the deck lower surface 14. The weighing element 87 comes into abutment with the two cross members 76a, 76b of the block 20E. The block 20E is part of the support structure that spaces the deck 10 from a supporting surface like a floor.

[0062] In this case, the contact between the weighing element 87 and the deck 10 is also determined by a spacing member 77. The spacing member 77 is arranged between the deck 10 and the weighing element 87. Here, the spacing member 77 is incorporated or included in the adhesive layer 85. The entire spacing member 77 is incorporated in the adhesive layer 85. The spacing member 77 is positioned at a centre portion of the weighing element 87.

[0063] FIG. 6 is a detail of another embodiment of the weighing element 87 of a load sensor device 71 in exploded perspective view. The weighing element 87 comprises a layered structure 82, 83, 84. The weighing element 87 has a top layer 82 and a bottom layer 84. This separation into layers facilitates introduction of electrical properties, like capacitance, between the top 82 and bottom layer 84 that can be varied and measured. Therefore, the weighing element 87 may comprise a number of measurement section. The number of measurement sections are spatially distributed over the weighing element 87 to facilitate discrimination between different modes of deformation of the deck 10.

[0064] The weighing element 87 has a core layer 83 between the top 82 and bottom layer 84. The core layer 83 has a cavity 86. In other words, the weighing element 87 comprises a pair of layers 82, 84 that form a cavity 86 in between the pair of layers 82, 84. The core layer 83, or also spacing layer 83, allows a neighbouring layer 82, 84 to deform. As a result, the top layer 82 can flex in unity with the deck 10.

[0065] In this case, the top 82, bottom 84, and core layer 83 do form a multilayer PCB. In other words, the weighing element 87 comprises a multilayer PCB 82, 83, 84. The multilayer PCB 82, 83, 84 has a spacing layer 83 that allows a neighbouring layer 82 to deform, in particular to flex in unity with the deck 10.

[0066] FIG. 7 shows an enlarged partially cut-away view of detail III in FIG. 1. According to this view, the deck 10 and part of the block 20I have been cut away to show the pallet construction. The deck 10 comprises an outer skin 11 of wood, covering an inner core 13 formed from slats of MDF material. In the illustrated embodiment, the skin 11 has a thickness of 3 mm. It will be understood that the outer skin may also be made of plywood, MDF or even of a composite e.g. laminated with fibre reinforced layers. Edge members 15, also of MDF, form the peripheral edge 16. These edge members 15 have a depth of 22 mm corresponding to the thickness of the core 13 and a width of 30 mm. This width is sufficient to allow cutaway regions 18 of around 15 mm, without unduly weakening the structure of the deck. The whole of the deck 10 is coated with a polyurethane resin coating 40, having a thickness of around 1 mm. The coating 40 provides a number of advantages to the pallet. Not only does it make the deck 10 stronger and more impact resistant but it is also waterproof, easily washable, anti-slip and can be used to provide a desirable colour or look.

[0067] The blocks 20 are also provided with the same coating 40 as the deck 10. They are glued to the deck 10 using an adhesive 42 that forms a relatively thick elastic bond between the elements. In the present embodiment, TEROSON MS 9399 is used, which is a two-component modified silane adhesive available from Henkel. An advantage of this adhesive is that it remains elastic even after curing and, while being sufficiently strong to prevent undesired separation, ensures shock absorption in case of impact on the pallet 10. The adhesive joint can also be easily broken using a cutting wire.

[0068] The skid 30 is also provided with the same coating 40, which covers it entirely. Adhesive 42 connects the skid 30 to the blocks 20. Also visible in this view are bumpers 44 provided on chamfers 17, 37 of the deck 10 and skid 30 respectively. The bumpers 44 are HDPE strips that are glued to and cover the chamfers 17, 37. Although not visible in this view, the bumpers 44 may be recessed into the material of the deck peripheral edge 16 and skid peripheral edge 36 respectively.

[0069] In production, the deck 10, blocks 20 and skid 30 are individually manufactured in the form as shown in FIG. 2. The finished elements are then all coated with coating 40 prior to assembly.

[0070] The blocks 20 are then adhered to the skid 30 using the adhesive 42 followed by application of the deck 10 with further adhesive 42 being placed onto the spacer portions 24 of the blocks 20. As a result, the deck 10 is spaced from a supporting surface and the deck 10 is free to deform as a unity in response to the weight of items placed on the deck 10.

[0071] In use, the sleeve portions 22 and the bumpers 44 fully protect the deck peripheral edge 16 and the skid peripheral edge 36 from any lateral shock due e.g. to incorrect insertion of a fork-lift into openings 4. In the case that damage does occur to the pallet 1, the elements that are damaged may be removed from the pallet 1 and replaced. In the case of damage to a single block 20, this may be removed by use of a wire cutter to cut adhesive 42 and separate the block 20 from the deck 10 and skid 30. This may involve first the removal of the sleeve portion 22 e.g. by cutting it away from the spacer portion 24. If the deck 10 or skid 30 is damaged, removal of all sleeve portions 22 may be desirable in order to conveniently cut away the blocks 20.

[0072] FIG. 8 gives a schematic overview of the architecture of electronic tag 60. Tag 60 includes a processor 61, a battery 62 an input-output device 63, antenna 64, memory 65 and clock 66, which operate in a conventional manner to enable the tag 60 to communicate over distances of up to 300 metres with a suitably arranged receiver according to standard protocols including Bluetooth, Wi-Fi, ZigBee, Zensys, LoRa, 6LoWPAN, 433 Mhz/868 Mhz/915 Mhz, 3G/4G/5G/LTE proprietary protocols or any other low power wide area network protocols.

[0073] The tag 60 is additionally provided with a temperature sensor 67, an accelerometer 68 and operationally coupled with the load sensor device 71, all of which communicate with the processor 61. It will be understood that other sensors may also be included as required. The load sensor device 71 is installed beneath the central block 20E and is calibrated during production to give a reading reflecting a distributed load supported on the deck 10. If required other calibrations may be applied depending on the nature of the product to be transported.

[0074] FIG. 9 gives a schematic overview of a pallet logistic system 100 according to one aspect of the invention. The system 100 comprises a plurality of pallets 1, a receiver 110, a network data server 120 and a customer server 130. The receiver 110, network data server 120 and customer server 130 are linked to each other through the Internet 140 and have Cloud data storage. The system 100 also includes a master pallet 1. The pallets 1 are as described above, each of which including a respective electronic tag 60. The master pallet 1 is otherwise identical to the pallets 1, with the exception that it includes additional communication capability in the form of a gateway device 70 having a 3G modem chip enabling it to communicate directly with a telecom provider. It will be understood that other levels of communication may be equally applicable including 4G, 5G, LTE or other. The gateway device 70 is also enabled to interrogate the tags 60 of any normal pallets 1 that are within range.

[0075] Operation of the system 100 will further be described with reference to FIGS. 8 and 9. In normal operation, the tags 60 on pallets 1 communicate wirelessly with the receiver 110 to the extent that they are in range. This may be the case when they enter or exit a warehouse facility, whereby the receiver 110 is located at an entrance or exit. The receiver 110 may also be mobile, e.g. located onboard a lorry, train or vessel. The tags 60 are set to ping or emit a signal containing status information at predetermined times. This time period varies according to the status of the pallet 1. If the pallet 1 is stationary, as determined by the accelerometer 68, the tag 60 pings every 60 minutes. If the accelerometer 68 detects motion of the pallet 1, the processor 61 instructs the input-output device 63 to ping every 60 seconds. In this manner, the life of battery 62 is preserved (these ping times are exemplary and may be varied according to the requirements of the situation).

[0076] The ping signal contains information stored by the memory 65 since the last communication with an external source. This may include data collected from the temperature sensor 67, the accelerometer 68 and the load sensor device 71, all of which is time stamped based on the clock 66 and provided with the pallet unique identity. In this manner, complete data relating to the environment in which the pallet 1 has found itself can be recorded and subsequently transmitted.

[0077] The ping signal is received by receiver 110, which acts as a gateway, for further transmission of the information to the internet 140. All this data is stored in the network data server 120, which will be used by the operator for operating the pallet pool. This network data server 120 will have the possibility to make available, via an Application Programming Interface or API, customer specific subsets of this data to customer servers 130 for use in their own IT systems.

[0078] In an alternative mode of operation, the gateway device 70 on the master pallet 1 is able to receive the ping signal from the pallets 1 when they are within range. This may be the case if the master pallet 1 is present in a consignment of normal pallets 1. In that case, the gateway device 70 may be able to continuously communicate data from the pallets 1 throughout their journey. The gateway device 70 can transmit this data directly to the internet 140.

[0079] It will be understood that based on the above system 100, the data that can be made available to the network data server 120 and the customer server 130 is limitless. Not only can data be generated in bulk relating to all pallets 1 within the system 100 but also individual data can be generated regarding the status of a particular pallet 1 and its load. The momentary position of a pallet 1 and its previous trajectory can be determined as can the environmental conditions (in this case temperature) to which it has been exposed. Additional sensors may be provided for all other detectable conditions that may be of interest. The condition of a pallet 1 may be determined by identifying sudden shocks or excessive loading using the respective accelerometer 68 and load sensors 69. This may be used to plan periodic maintenance or checks. Additionally, an individual pallet 1 may be interrogated by scanning the identity in a suitable manner to directly determine its status. For example a barcode allows an enabled mobile device such as a smartphone to extract data from the Internet 140 relating to recently received information transmitted from the tag 60 on the pallet 1.