Modular fork assembly for a forked material-handling vehicle

A pallet truck including a fork assembly configured for lifting a pallet having one or more upper planks, the pallet truck comprising:

• a steer wheel;
• a chassis operatively connected to the steer wheel;
• and
• two substantially parallel first and second fork assemblies operatively connected to and extending from the chassis and configured to hold a load for conveyance by the pallet truck as the pallet truck moves;
• wherein the first fork assembly comprises:
• a first discrete elongate body having a first elongate body upper surface;
• a first discrete load wheel module having a first load wheel frame and a first load wheel module upper surface and one or more first load wheels, wherein the first load wheel module is configured for moving the one or more first load wheels between an first undeployed position and a first deployed position, wherein the one or more first load wheels in the first undeployed position are at least partly surrounded by the first load wheel frame, wherein the first load wheel module is configured for fitting beneath the one or more upper planks of a pallet when the one or more first load wheels are in the first undeployed position, and wherein a first majority of a first wheel height of the one or more first load wheels extends beyond the first load wheel frame in the first deployed position;
• a first proximal interlocking mechanism detachably connecting the first elongate body to the first load wheel module;
• a discrete first fork tip configured for fitting beneath the one or more upper planks of a pallet;
• and
• a first distal interlocking mechanism detachably connecting the first load wheel module to the first fork tip, wherein the first load wheel module is positioned between the first elongate body and the first fork tip, and wherein the first elongate body upper surface and the first load wheel module upper surface are substantially coplanar;
• and
• wherein the second fork assembly comprises:
• a second discrete elongate body having an second elongate body upper surface;
• a second discrete load wheel module having a second load wheel frame and a second load wheel module upper surface and one or more second load wheels, wherein the second load wheel module is configured for moving the one or more second load wheels between an second undeployed position and a second deployed position, wherein the one or more second load wheels in the second undeployed position are at least partly surrounded by the second load wheel frame, wherein the second load wheel module is configured for fitting beneath the one or more upper planks of a pallet when the one or more second load wheels are in the second undeployed position, and wherein a second majority of a second wheel height of the one or more second load wheels extends beyond the second load wheel frame in the second deployed position;
• a second proximal interlocking mechanism detachably connecting the second elongate body to the second load wheel module;
• a discrete second fork tip configured for fitting beneath the one or more upper planks of a pallet;
• and
• a second distal interlocking mechanism detachably connecting the second load wheel module to the second fork tip, wherein the second load wheel module is positioned between the second elongate body and the second fork tip, and wherein the second elongate body upper surface and the second load wheel module upper surface are substantially coplanar.

An inventory of parts for a forked material-handling vehicle configured for lifting a pallet having one or more upper planks, the inventory comprising:

• multiple interchangeable elongate bodies having respective elongate body upper surfaces, wherein the multiple interchangeable elongate bodies include a first elongate body having a first elongate body upper surface and a second elongate body having a second elongate body upper surface;
• multiple interchangeable load wheel modules having respective load wheel module upper surfaces, wherein the multiple interchangeable load wheel modules include a first load wheel module and a second load wheel module, wherein the first load wheel module has a first load wheel frame and a first load wheel module upper surface and one or more first load wheels, wherein the first load wheel module is configured for moving the one or more first load wheels between an first undeployed position and a first deployed position, wherein the one or more first load wheels in the first undeployed position are at least partly surrounded by the first load wheel frame, wherein the first load wheel module is configured for fitting beneath the one or more upper planks of a pallet when the one or more first load wheels are in the first undeployed position, wherein a first majority of a first wheel height of the one or more first load wheels extends beyond the first load wheel frame in the first deployed position, wherein the second load wheel module has a second load wheel frame and a second load wheel module upper surface and one or more second load wheels, wherein the second load wheel module is configured for moving the one or more second load wheels between an second undeployed position and a second deployed position, wherein the one or more second load wheels in the second undeployed position are at least partly surrounded by the second load wheel frame, wherein the second load wheel module is configured for fitting beneath the one or more upper planks of a pallet when the one or more second load wheels are in the second undeployed position, and wherein a second majority of a second wheel height of the one or more second load wheels extends beyond the second load wheel frame in the second deployed position;
• multiple interchangeable proximal interlocking mechanism components configured for detachable connection of any one of the multiple interchangeable elongate bodies to any one of the multiple interchangeable load wheel modules such that the respective elongate body upper surface and the respective load wheel module upper surface are aligned to be substantially coplanar;
• multiple interchangeable fork tips, including a first fork tip and a second fork tip, wherein the first fork tip and second for tip are configured for fitting beneath the one or more upper planks of a pallet;
• and
• multiple distal interlocking proximal mechanism components configured for detachable connection of any one of the multiple interchangeable fork tips to any one of the multiple interchangeable load wheel modules.