Test Plan for the Pallet Prototype

Test Plan for the pallet prototype

Introduction

The new pallet for Liner Cell is needed to provide safety and improve productivity. A new pallet can improve productivity by providing a new platform for moving a liner around the cell and the DR plant. The new pallet needs to go through a test procedure in order to prove the concept.

The test will involve taking a prototype pallet and placing a liner onto it. Then the liner will be held in place by a tie-down strap. After an inspection of the pallet, a fork truck driver will move the pallet around the DR facility. This procedure will prove that the pallet is capable of retaining the liner under normal circumstances.

Initial inspection

There are no initial fractures in the pallet or v-blocks.

Testing

The forklift operator moved the prototype pallets loaded with liners at working speed (approx. 3-4 mph). Motions included:

• Circular Movement- Forklift operator made one complete 360 degree turn with forklift.
• Forward Motion- Forklift operator drove forward straight for 30 ft with forklift.
• Backward Motion- Forklift operator drove in reverse straight for 30 ft with forklift.

The liners tested were:

• One large liner (30” Diameter, 53” Length)
• Two smaller liners (18” Diameter, 46” Length and 8” Diameter, 46” Length)

Results

Single Large Liner Results

Dual Smaller Liner Results

Overall, the test was a success. There was no damage to the liner and the pallet maintained structural integrity. There were no fractures in the pallet or the v-blocks. The strap held the liner in place securely. The liner did not move at all under the conditions that it was subjected to. There is an issue with the strap housing lifting up off the pallet when a liner is installed. It is a direct effect of the strap having only one mounting hole. The issue will not cause any interference with the operation of the strap. However, it may cause the mounting point to fail at some point from the continuous fatigue induced from the loading and unloading of liners.

Pallet Assembly

The final pallet configuration used in the testing revealed several changes that should be taken into account when mass producing a number of pallets based on the cells needs. Some of these changes are:

• Different material:
• Although the pine pallet held up fine strength and stability wise, the durability and longevity of this material will be lacking. A different material such as oak or a plastic molded design would be better suited. Also reinforcement at the strap locations will also be necessary in order for the repeated use of the pallet to not tear the straps out.
• Strap Mount:
• As noted earlier, the strap bracket was deflecting under the load, a solution such as a custom mounting plate or bracket on a 45 degree angle could solve these problems.

The pallet prototype was based on a 42” x 42” standard industry pallet. This seemed to work well for most liner applications in testing however a different size may be used to fit in with plant standards. As long as the top slats are positioned in a way to support the V-Blocks and they are sufficient in thickness to accommodate the load.