Design Process

The orientation of the boxes within each layer of the pallet proved to be an interesting challenge. While it may not be intuitive, a uniform box orientation between each layer on the pallet can cause stability problems due to 'free-standing' columns of boxes on top of each other.

By using a novel method of varying the orientation of the boxes from layer to layer (see above) stability can be vastly improved by breaking up such columns using the interlay of boxes. This method of course introduced the need for a method of orienting the boxes in two different directions and thus a 'bump turner' system was conceived and implemented.

Relevant simulations and calculations were preformed to ensure the physical functionality of the design.

Available components, fasteners and electronics were collected from disassembled previous projects. They were sorted and categorised, and selected for various mechanisms, where usable.

Many components had to be designed from scratch. Solidwords models and drawings were used to record these designs, which were based on simplicity of manufacture and functionality.

The design was brought together in a full assembly model and real life build.