Extremely-high stacking skillful fixing frame device

Abstract

The invention provides a super-height stacking skillful fixing frame device, which belongs to the technical field of logistics storage or port transportation, and comprises a rectangular chassis, a reinforced upright post, an opening design top component, a precise positioning clamping groove device and an intelligent monitoring system. The chassis is uniformly stressed by alternately arranging hollow square tubes and equilateral angle steel; the stand column structure comprises a main supporting component and an auxiliary supporting component to improve the vertical bearing capacity. The top component adapts to cargo gravity center adjustment through opening design; the accurate positioning device achieves accurate clamping of the upper layer and the lower layer through a 82-degree non-standard angle steel clamping groove, changes a stress model and improves the structural strength. The intelligent monitoring system monitors the center-of-gravity position of the goods in real time through the weighing sensor, and stacking safety is ensured. The device breaks through the limitation of the traditional height of 5 meters, and realizes stable stacking of five layers at the height of 6 meters.

Description

Technical Field

[0001] The present invention belongs to the technical field of logistics warehousing or port transportation. Specifically, it relates to a nesting pallet rack device for ultra-high stacking. Background Art

[0002] In the field of logistics warehousing, nesting pallet racks, as important cargo turnover devices, are widely used in the links of commodity storage, transportation, and distribution. Traditional nesting pallet racks mainly consist of a chassis, columns, and top members, and stacking operations are achieved manually or by forklifts. With the improvement of warehousing automation, unmanned forklifts are gradually applied to the stacking operations of nesting pallet racks to improve operation efficiency and space utilization.

[0003] However, traditional nesting pallet racks have many defects during ultra-high stacking: Firstly, the connection structure between the chassis and the top member is simple and lacks a precise positioning mechanism, resulting in easy misalignment between the upper and lower layers of nesting pallet racks; Secondly, the nesting pallet rack lacks the ability to monitor the real-time center of gravity of the goods, making uneven placement of the goods likely to cause structural instability; Moreover, the design strength of the columns of traditional nesting pallet racks is insufficient and it is difficult to meet the load requirements of ultra-high stacking.

[0004] When an unmanned forklift performs ultra-high stacking operations, the blind spot of vision above 5 meters makes the operation more difficult. Traditional nesting pallet racks lack a precise positioning device and an intelligent monitoring system, and cannot ensure stacking accuracy and structural stability, resulting in greater safety hazards in ultra-high stacking operations. This makes how to improve the positioning accuracy of nesting pallet racks and ensure the safety of ultra-high stacking an urgent technical problem to be solved. Summary of the Invention

[0005] In view of this, the present invention provides a nesting pallet rack device for ultra-high stacking, which can solve the technical problem of poor safety of ultra-high stacking caused by insufficient positioning accuracy when a forklift stacks a nesting pallet rack in the prior art.

[0006] The present invention is implemented as follows: The present invention provides a nesting pallet rack device for ultra-high stacking. The chassis is set as a rectangular structure, and the columns are arranged at the four corners of the chassis; the top member is arranged at the top of the columns and adopts an open design; the precise positioning device includes slots arranged on both sides of the chassis edge and facing the ground side, and slots arranged on both sides of the top member and facing the upper side; when the slots of the top member correspond to the slots of the chassis, each side of the slots is moved inward by a certain distance, so that the force model of the nesting pallet rack changes from a simply supported beam to a cantilever beam, reducing the internal force of each bending deformation member of the chassis; the intelligent monitoring system includes a bending beam type weighing sensor and an identification mark, which are used to detect the position of the center of gravity of the loaded goods and realize the binding management of the nesting pallet rack and the goods.

[0007] Among them, the chassis is formed by welding hollow square tubes to form a main frame. Hollow square tubes are arranged along the long sides of the rectangle, and hollow square tubes are arranged along the short sides of the rectangle; inside the main frame of the chassis, hollow square tubes and equal-angle steel are arranged alternately from left to right and welded to the main frame of the chassis; the equal-angle steel evenly divides the chassis into zones, which is used to adjust the center of gravity of the goods and make the force on the chassis uniform.

[0008] Among them, the column includes a thickened hollow square tube as the main support member and a hollow square tube as the auxiliary support member; the main support member bears the main compressive deformation load, and the auxiliary support member reduces the internal force borne by the column.

[0009] Among them, the top member is made of angle steel on both the left and right sides, and triangular stiffeners are built inside the angle steel; the top member is designed with an opening, taking advantage of the instability of the parallelogram to adjust the distance between the left and right side members according to the position of the center of gravity of the goods.

[0010] Among them, in the precise positioning device, the card slots at the edges on both sides of the chassis are set as non-standard angle steel card slots, facing the ground side; the card slots on both sides of the top member are set as corresponding angle card slots facing upward.

[0011] Among them, the bending beam type load cell is arranged at the four corners of the front, back, left and right of the chassis to detect the position of the center of gravity of the loaded goods; the identification mark is arranged on the outer surface of the cage pallet to realize the binding management of the cage pallet and the goods.

[0012] Among them, when the cage pallet is in the single-layer use state, the chassis bears the weight of the goods, and the bending beam type load cell detects the center of gravity of the goods to ensure that the goods are at the center position of the cage pallet; when the cage pallet is in the first layer of the stacking state, the chassis directly contacts the ground, and the chassis card slots of the upper cage pallet are accurately docked with the top member card slots of this layer; when the cage pallet is in the middle layer of the stacking state, the chassis card slots are accurately engaged with the top member card slots of the lower cage pallet, and the top member card slots are accurately engaged with the chassis card slots of the upper cage pallet to form a stable connection.

[0013] Among them, it also includes determining the optimal layout of the hollow square tubes and equal-angle steel on the chassis by using the chassis support structure layout optimization method. The input parameters include the chassis width parameter, the hollow square tube width parameter, the equal-angle steel width parameter, the hollow square tube quantity parameter, the equal-angle steel quantity parameter, and the spacing variance threshold parameter, and the output parameter is the support structure layout scheme parameter.

[0014] Among them, it also includes determining the maximum safe stacking height of the cage pallet by using the column bearing capacity calculation method. The input parameters include the elastic modulus parameter of the column material, the moment of inertia parameter of the column section, the column height parameter, the full-load weight parameter of a single-layer cage pallet, and the safety factor parameter, and the output parameter is the maximum safe stacking layer number parameter.

[0015] Among them, it also includes calculating the critical tipping angle of the stacking structure by using the stacking stability calculation method. The input parameters include the stacking height parameter, the chassis width parameter, the center of gravity height parameter of the goods, the weight parameter of a single-layer cage, the weight parameter of the goods, and the gravitational acceleration parameter. The output parameter is the critical tipping angle parameter.

[0016] Through the design of the 82° non-standard angle steel card slots between the chassis and the top member, the present invention realizes the precise clamping connection of the upper and lower layer cages. This design makes each side of the card slot move 40 mm inward, and the force-bearing model of the cage changes from a simply supported beam to a cantilever beam, effectively reducing the internal force of each bending and deforming member of the chassis.

[0017] The precise positioning device designed by the present invention solves the problem of insufficient positioning accuracy of traditional cages, enabling the unmanned forklift to achieve ultra-high stacking operations, and ensuring accurate positioning even in the blind area of the operation line of sight. At the same time, the integrated intelligent monitoring system real-time detects the position of the center of gravity of the goods through the bending beam type weighing sensor, ensuring uniform force on the stacking structure and improving the overall stability.

[0018] Through the optimized design of the column structure, the present invention bears the main compression deformation load, and the chassis structure evenly divides the area to adjust the center of gravity of the goods, making the force on the chassis uniform, solving the technical problem of poor safety in ultra-high stacking, and providing a safer and more efficient goods turnover solution for automated warehousing logistics. Brief Description of the Drawings

[0019] Figure 1 It is a schematic diagram of the overall structure of the cage in Embodiment 2;

[0020] Figure 2 It is a schematic diagram of the chassis structure of the cage in Embodiment 2;

[0021] Figure 3 It is a schematic diagram of the column structure of the cage in Embodiment 2;

[0022] Figure 4 It is a schematic diagram of the top member of the cage in Embodiment 2;

[0023] Figure 5 It is a schematic diagram of the precise positioning device of the cage in Embodiment 2;

[0024] Figure 6 It is a schematic diagram of the intelligent monitoring system of the cage in Embodiment 2;

[0025] Figure 7 It is a schematic diagram of the stacking structure of the cage in Embodiment 2;

[0026] Among them, the reference numerals in the drawings:

[0027] 1. Chassis; 10. Bending beam weighing sensor; 11. Main supporting column; 12. Auxiliary supporting column; 16. Chassis slot; 17. Top member slot; 2. Column; 3. Top member; 4. Positioning device; 6. Main frame; 8. Equilateral angle steel; 9. RFID tag. DETAILED DESCRIPTION

[0028] In order to make the purpose, technical solution and advantages of the embodiments of the present invention more clear, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention.

[0029] like Figure 1 As shown, a smart fixing frame device for ultra-high stacking provided by the present invention comprises:

[0030] Chassis, columns, top components, precise positioning devices, intelligent monitoring systems;

[0031] The chassis is set as a rectangular structure, with 6 50×50×2 hollow square tubes welded to form the main frame, 4 hollow square tubes are set along the long sides of the rectangle, and 2 hollow square tubes are set along the short sides of the rectangle; 9 50×50×2 hollow square tubes and 12 50×50×3 equilateral angle steels are evenly arranged and welded to the chassis main frame from left to right; the equilateral angle steels divide the chassis into even sections, which are used to adjust the center of gravity of the cargo and make the chassis evenly stressed;

[0032] The columns are set at the four corners of the chassis, including 4 50×50×2.75 thickened hollow square tubes as the main support components and several 30×30×1.5 hollow square tubes as auxiliary support components; the main support components bear the main compression deformation load, and the auxiliary support components reduce the internal force of the columns;

[0033] The top member is set at the top of the four columns. The left and right sides of the top member are made of angle steel, and the angle steel has built-in triangular ribs. The top member adopts an open design, and the distance between the left and right members is adjusted according to the center of gravity of the cargo by using the parallelogram instability.

[0034] The precise positioning device includes a non-standard angle steel slot set at the edges of both sides of the chassis and facing the ground with an angle of 82°, and a slot set at both sides of the top member and facing upward with a corresponding angle; when the top member slot corresponds to the chassis slot 16, the two sides of the slot are moved inward by 40 mm, so that the force model of the clever fixing frame changes from a simply supported beam to an outwardly extending beam, reducing the internal force of each bending and deformation member of the chassis;

[0035] The intelligent monitoring system includes 8 bending beam type load cells and RFID tags or QR code identification marks; the bending beam type load cells are arranged at two corners each in the front, back, left, and right of the chassis, and are used to detect the gravity center position of the loaded goods; the RFID tags or QR code identification marks are arranged on the outer surface of the cage pallet, and are used to realize the binding management of the cage pallet and the goods;

[0036] When the cage pallet is in the single-layer use state, the chassis bears the weight of the goods, and the bending beam type load cells detect the gravity center of the goods to ensure that the goods are at the center position of the cage pallet;

[0037] When the cage pallet is in the first layer of the stacking state, the chassis directly contacts the ground, and the chassis card slots of the upper cage pallet are accurately docked with the card slots of the top members of this layer;

[0038] When the cage pallet is in the middle layer of the stacking state, the chassis card slots are accurately engaged with the card slots of the top members of the lower cage pallet, and the card slots of the top members are accurately engaged with the chassis card slots of the upper cage pallet to form a stable connection;

[0039] When the cage pallet is in the top layer of the stacking state, the chassis card slots are accurately engaged with the card slots of the top members of the lower cage pallet, and the card slots of the top members are exposed to the external environment;

[0040] When the driverless forklift performs the ultra-high stacking operation, first lower the rear of the cage pallet for positioning, and then adjust the left and right positions of the front according to the gravity center position of the goods to achieve the accurate positioning of adjacent two-layer cage pallets; after stacking, a five-layer stacking structure is formed, and the total height reaches 6 meters, breaking through the limitation of the traditional 5-meter line-of-sight blind area;

[0041] The calculation method for the positional relationship between the chassis card slots and the top member card slots is used to determine the accurate docking position when the upper and lower layer cage pallets are stacked. The input parameters of the calculation method for the positional relationship between the chassis card slots and the top member card slots include the chassis length parameter, the chassis width parameter, the card slot angle parameter, the card slot inner shift distance parameter, and the column height parameter. The output parameter of the calculation method for the positional relationship between the chassis card slots and the top member card slots is the maximum allowable offset parameter between the upper and lower layer cage pallets; among them, the chassis length parameter is obtained by measuring the long side of the chassis main frame, the chassis width parameter is obtained by measuring the short side of the chassis main frame, the card slot angle parameter is 82°, the card slot inner shift distance parameter is 40 mm, and the column height parameter is obtained by measuring the length of the main support member; the maximum allowable offset parameter is used to guide the accuracy control during the stacking operation of the driverless forklift;

[0042] The calculation method for the center-of-gravity position of the goods is used to determine the center-of-gravity coordinates of the goods based on the readings of the bending beam type load cells. The input parameters of the calculation method for the center-of-gravity position of the goods include the load cell reading parameters at the four corners, the chassis length parameter, and the chassis width parameter. The output parameter of the calculation method for the center-of-gravity position of the goods is the center-of-gravity offset coordinate parameter. Among them, the load cell reading parameters at the four corners are obtained by real-time acquisition through the bending beam type load cells installed at the four corners of the chassis. The chassis length parameter is obtained by measuring the long side of the main frame of the chassis. The chassis width parameter is obtained by measuring the short side of the main frame of the chassis. The center-of-gravity offset coordinate parameter is used to evaluate whether the placement of the goods is reasonable and to guide the unmanned forklift to adjust the stacking posture.

[0043] The calculation method for the column load-bearing capacity is used to determine the maximum safe stacking height of the cage pallet rack. The input parameters of the calculation method for the column load-bearing capacity include the elastic modulus parameter of the column material, the moment of inertia parameter of the column cross-section, the column height parameter, the full-load weight parameter of a single-layer cage pallet rack, and the safety factor parameter. The output parameter of the calculation method for the column load-bearing capacity is the maximum safe stacking layer number parameter. Among them, the elastic modulus parameter of the column material is obtained according to the specifications of the steel used. The moment of inertia parameter of the column cross-section is obtained by calculating the column cross-section size. The column height parameter is obtained by measuring the length of the main support member. The full-load weight parameter of a single-layer cage pallet rack is obtained by measuring with a bending beam type load cell. The safety factor parameter is determined according to industry standards. The maximum safe stacking layer number parameter is used to limit the maximum stacking height of the cage pallet rack to ensure structural safety.

[0044] The calculation method for the relationship between the square tube thickness and the load-bearing capacity is used to determine the minimum thickness requirement of the chassis square tube. The input parameters of the calculation method for the relationship between the square tube thickness and the load-bearing capacity include the square tube side length parameter, the square tube length parameter, the load parameter, the material yield strength parameter, and the safety factor parameter. The output parameter of the calculation method for the relationship between the square tube thickness and the load-bearing capacity is the square tube minimum thickness parameter. Among them, the square tube side length parameter is the outer side length of the cross-section of the hollow square tube. The square tube length parameter is the actual length of the hollow square tube. The load parameter is the total weight borne by the cage pallet rack in the full-load state. The material yield strength parameter is obtained according to the specifications of the steel used. The safety factor parameter is determined according to industry standards. The square tube minimum thickness parameter is used to guide the selection of the hollow square tube for the chassis.

[0045] The stacking stability calculation method is used to calculate the critical tipping angle of the stacking structure. The input parameters of the stacking stability calculation method include the stacking height parameter, the chassis width parameter, the center of gravity height parameter of the goods, the weight parameter of a single-layer Kwikstage, the weight parameter of the goods, and the gravitational acceleration parameter. The output parameter of the stacking stability calculation method is the critical tipping angle parameter. Among them, the stacking height parameter is the total height after stacking multiple layers of Kwikstages. The chassis width parameter is obtained by measuring the short side of the chassis main frame. The center of gravity height parameter of the goods is obtained by the calculation method of the center of gravity position of the goods. The weight parameter of a single-layer Kwikstage is the self-weight of the empty Kwikstage. The weight parameter of the goods is obtained by measuring with a bending beam type weighing sensor. The gravitational acceleration parameter is a fixed value of 9.8 m / s². The critical tipping angle parameter is used to evaluate the stability of the Kwikstage stacking structure.

[0046] The layout optimization method of the chassis support structure is used to determine the optimal layout of the hollow square tubes and equal-angle steel on the chassis. The input parameters of the layout optimization method of the chassis support structure include the chassis width parameter, the width parameter of the hollow square tube, the width parameter of the equal-angle steel, the quantity parameter of the hollow square tube, the quantity parameter of the equal-angle steel, and the spacing variance threshold parameter. The output parameter of the layout optimization method of the chassis support structure is the support structure layout scheme parameter. Among them, the chassis width parameter is obtained by measuring the short side of the chassis main frame. The width parameter of the hollow square tube is 50 mm. The width parameter of the equal-angle steel is 50 mm. The quantity parameter of the hollow square tube is 9. The quantity parameter of the equal-angle steel is 12. The spacing variance threshold parameter is the allowable range of change in the support structure spacing. The support structure layout scheme parameter is used to guide the manufacture and installation of the chassis support structure.

[0047] Preferably, the chassis main body is welded into a rectangular structure by 6 hollow square tubes of 50×50×2, with a length of 1350 mm and a width of 1150 mm.

[0048] Preferably, 9 hollow square tubes of 50×50×2 and 12 equal-angle steel of 50×50×3 are arranged inside the chassis, and the hollow square tubes and the equal-angle steel are evenly arranged alternately along the chassis width direction.

[0049] Preferably, the equal-angle steel on the chassis divides the chassis into 13 regions evenly, which is convenient for adjusting the center of gravity when placing goods.

[0050] Preferably, the height of the column is 1150 mm, and 4 main support columns are made of thickened hollow square tubes of 50×50×2.75 to enhance the load-bearing capacity.

[0051] Preferably, the column 19 is made of a hollow square tube of 30×30×1.5 and is used to connect the main support columns to strengthen the overall rigidity of the Kwikstage.

[0052] Preferably, the left and right sides of the top member are made of angle steel 14, and triangular gusset plates are built into the angle steel to increase the bearing capacity;

[0053] Preferably, the chassis card slot is designed with an 82° non-standard angle steel to ensure precise clamping with the chassis card slot of the upper tier pallet rack;

[0054] Preferably, compared with the corresponding positions of the top member card slot and the chassis card slot, both sides move 40 mm inward respectively, changing the stress state and improving the structural strength;

[0055] Preferably, 8 bending beam type load cells are distributed at the four corners of the chassis, with 2 at each corner, for accurately monitoring the center of gravity of the goods;

[0056] Preferably, the weight of a single pallet rack is about 80 kg, and the total weight of the goods and the pallet rack during five-layer stacking is about 9 tons, meeting the requirements of ultra-high stacking strength;

[0057] Among them, the chassis length parameter refers to the external dimension of the chassis main frame along the long side direction; the chassis width parameter refers to the external dimension of the chassis main frame along the short side direction; the slot angle parameter refers to the included angle formed by the chassis slot or the top member slot and the horizontal plane; the slot inward displacement distance parameter refers to the distance that the top member slot offsets inward relative to the chassis slot; the column height parameter refers to the vertical distance from the upper surface of the chassis to the lower surface of the top member; the maximum allowable offset parameter refers to the maximum horizontal offset distance allowed between the upper and lower adjacent levels of the rack in the stacked state; the four-corner load cell reading parameter refers to the weight value measured by the bending beam load cell at the four corners of the chassis; the cargo center of gravity offset coordinate parameter refers to the horizontal position offset of the cargo center of gravity relative to the center point of the chassis; the column material elastic modulus parameter refers to the elastic modulus value of the steel used for the column; the column section moment of inertia parameter refers to the second moment of the column cross-section about the neutral axis; the full-load weight parameter of a single-layer rack refers to the total weight after a rack is filled with goods; the safety factor parameter refers to the safety margin coefficient increased after considering various uncertain factors; the square tube side length parameter refers to the external side length of the cross-section of the hollow square tube; the square tube length parameter refers to the axial length of the hollow square tube; the load parameter refers to the external force acting on the structure; the material yield strength parameter refers to the stress value when the material begins to produce plastic deformation; the minimum thickness parameter of the square tube refers to the minimum allowable value of the wall thickness of the hollow square tube; the stacking height parameter refers to the vertical distance from the ground to the top of the topmost layer of the multi-layer rack after stacking; the cargo center of gravity height parameter refers to the vertical height of the cargo center of gravity from the ground; the weight parameter of a single-layer rack refers to the self-weight of the empty rack; the cargo weight parameter refers to the total weight of the goods loaded in the rack; the gravitational acceleration parameter refers to the value of the gravitational acceleration on the earth's surface; the critical tipping angle parameter refers to the inclination angle when the stacking structure begins to tip over; the hollow square tube width parameter refers to the external width of the cross-section of the hollow square tube; the equal-angle steel width parameter refers to the side length of the cross-section of the equal-angle steel; the hollow square tube quantity parameter refers to the total number of hollow square tubes used in the chassis; the equal-angle steel quantity parameter refers to the total number of equal-angle steels used in the chassis; the spacing variance threshold parameter refers to the maximum range of allowable variation in the spacing of the support structure; the support structure layout scheme parameter refers to the specific position layout of the hollow square tubes and equal-angle steels on the chassis.

[0058] The following describes the specific implementation manners of the above steps in detail.

[0059] This embodiment provides a rack device for ultra-high stacking, which includes a chassis, columns, top members, a precise positioning device, and an intelligent monitoring system. Through a unique structural design and calculation method, this rack device can achieve a stacking height exceeding the traditional 5-meter line-of-sight blind area limit, reaching a total height of 6 meters, while ensuring structural stability and safety.

[0060] The ultra-high stacking smart rack device adopts a modular design. Each unit consists of a chassis, columns, and a top component. It can be used alone or in multiple layers. The chassis adopts a rectangular structure with columns at the four corners. The top component connects the four columns to form a complete frame. Precision positioning devices are set on the chassis and the top component to ensure stable docking during multi-layer stacking. The intelligent monitoring system monitors and manages the goods and smart racks through sensors and identification tags.

[0061] When the smart frame is stacked in multiple layers, the bottom smart frame directly contacts the ground, the middle smart frame is precisely connected with the upper and lower smart frames through the slot mechanism, and the top component slot of the top smart frame is exposed to the external environment. The entire stacking structure can reach five layers with a total height of 6 meters, breaking through the traditional blind spot limitation. At the same time, the special slot design changes the stress state and improves the overall structural strength and stability.

[0062] The chassis is set as a rectangular structure, and the main frame is formed by welding 6 50×50×2 hollow square tubes. Among them, 4 hollow square tubes are set along the long side of the rectangle, and 2 hollow square tubes are set along the short side of the rectangle. The length of the chassis main frame is 1350mm and the width is 1150mm.

[0063] There are 9 50×50×2 hollow square tubes and 12 50×50×3 equilateral angle steels from left to right in the chassis main frame, which are evenly arranged and welded on the chassis main frame. The equilateral angle steels divide the chassis into 13 areas, which is convenient for adjusting the center of gravity when placing goods and making the chassis evenly stressed. The hollow square tubes and equilateral angle steels are evenly arranged and alternately arranged along the width of the chassis to form a grid-like support structure to enhance the strength of the chassis.

[0064] The chassis support structure layout optimization method is used to determine the optimal layout of hollow square tubes and equilateral angle steels on the chassis. The input parameters of this method include chassis width parameter, hollow square tube width parameter, equilateral angle steel width parameter, hollow square tube quantity parameter, equilateral angle steel quantity parameter, and spacing variance threshold parameter. The chassis width parameter is 1150mm, the hollow square tube width parameter is 50mm, the equilateral angle steel width parameter is 50mm, the hollow square tube quantity parameter is 9, the equilateral angle steel quantity parameter is 12, and the spacing variance threshold parameter is the allowable support structure spacing variation range. The output parameters of this method are the support structure layout scheme parameters, which are used to guide the manufacture and installation of the chassis support structure.

[0065] The calculation method for the relationship between the thickness of the square tube and its load-bearing capacity is used to determine the minimum thickness requirement of the square tube for the chassis. The input parameters of this method include the side length parameter of the square tube, the length parameter of the square tube, the load parameter, the material yield strength parameter, and the safety factor parameter. The output parameter of this method is the minimum thickness parameter of the square tube, which is used to guide the selection of the hollow square tube for the chassis. Through this calculation method, it is determined that the main frame of the chassis adopts a 50×50×2 hollow square tube, and the internal support also adopts a 50×50×2 hollow square tube and 50×50×3 equal-angle steel.

[0066] The columns are arranged at the four corners of the chassis, including 4 50×50×2.75 thickened hollow square tubes as the main support members and several 30×30×1.5 hollow square tubes as the auxiliary support members. The main support members bear the main compressive deformation load, and the auxiliary support members reduce the internal force borne by the columns. The height of the columns is 1150mm, and the main support columns are made of thickened hollow square tubes to enhance the load-bearing capacity.

[0067] The auxiliary support columns are made of 30×30×1.5 hollow square tubes and are used to connect the main support columns to strengthen the overall rigidity of the strong-fixation frame. The auxiliary support columns are fixed between the main support columns by welding to form a triangular support structure, reducing the deformation of the main support columns under pressure.

[0068] The calculation method for the load-bearing capacity of the columns is used to determine the maximum safe stacking height of the strong-fixation frame. The input parameters of this method include the elastic modulus parameter of the column material, the moment of inertia parameter of the column section, the column height parameter, the full-load weight parameter of a single-layer strong-fixation frame, and the safety factor parameter. The output parameter of this method is the maximum safe stacking layer number parameter, which is used to limit the maximum stacking height of the strong-fixation frame to ensure structural safety. Through this calculation method, it is determined that the strong-fixation frame can be safely stacked up to five layers, with a total height of 6 meters.

[0069] The top member is arranged at the top of the 4 columns. The left and right sides of the top member are made of angle steel, and triangular stiffeners are built inside the angle steel to increase the load-bearing capacity. The top member adopts an open design, taking advantage of the instability of the parallelogram to adjust the distance between the left and right side members according to the position of the center of gravity of the goods.

[0070] The triangular stiffeners built inside the angle steel of the top member are fixed by welding to enhance the bending resistance of the angle steel. The open design enables the top member to deform appropriately according to the position of the center of gravity of the goods, improving adaptability while ensuring structural strength. When the center of gravity of the goods shifts, slight deformations will occur on both sides of the top member, enabling the entire strong-fixation frame to better adapt to goods with different center-of-gravity positions.

[0071] The precise positioning device includes non-standard angle steel card slots set at both side edges of the chassis and facing the ground side at an angle of 82°, and card slots set at both sides of the top member and facing upward at corresponding angles. When the card slots of the top member correspond to those of the chassis, each side of the card slot is moved 40 mm inward, changing the force-bearing model of the pallet rack from a simply supported beam to a cantilever beam, reducing the internal force of each flexurally deformed member of the chassis.

[0072] The chassis card slots are designed with 82° non-standard angle steel to ensure precise clamping with the chassis card slots of the upper-layer pallet rack. This angle design enables the upper and lower-layer pallet racks to automatically align during stacking, reducing operation errors. Compared with the corresponding positions of the card slots of the top member and the chassis card slots, each side is moved 40 mm inward, changing the force-bearing state and improving the structural strength.

[0073] The calculation method for the positional relationship between the chassis card slots and the top member card slots is used to determine the precise docking position when stacking the upper and lower-layer pallet racks. The input parameters of this method include the chassis length parameter, chassis width parameter, card slot angle parameter, card slot inward movement distance parameter, and column height parameter. The output parameter of this method is the maximum allowable offset parameter between the upper and lower-layer pallet racks, which is used to guide the precision control during the stacking operation of the automated forklift.

[0074] The intelligent monitoring system includes 8 bending beam type weighing sensors and RFID tags or two-dimensional code identification marks. Two bending beam type weighing sensors are set at each of the four corners of the front, back, left, and right of the chassis, which are used to detect the center of gravity position of the loaded goods. The RFID tags or two-dimensional code identification marks are set on the outer surface of the pallet rack, which are used to realize the binding management of the pallet rack and the goods.

[0075] The 8 bending beam type weighing sensors are distributed at the four corners of the chassis, with 2 sensors set at each corner, which are used to accurately monitor the center of gravity of the goods. The sensors are fixed under the chassis by bolts, which can real-time monitor the force conditions at each point and transmit data to the control system by wired or wireless means. The RFID tags or two-dimensional code identification marks are fixed at obvious positions on the outer side of the pallet rack for easy scanning and identification.

[0076] The calculation method for the center of gravity position of the goods is used to determine the center of gravity coordinates of the goods according to the readings of the bending beam type weighing sensors. The input parameters of this method include the readings parameter of the four-corner weighing sensors, the chassis length parameter, and the chassis width parameter. The output parameter of this method is the center of gravity offset coordinate parameter, which is used to evaluate whether the goods are placed reasonably and to guide the automated forklift to adjust the stacking posture.

[0077] The weight of a single pallet rack is about 80 kg, and the total weight of the goods and the pallet racks during five-layer stacking is about 9 tons, meeting the requirements for the strength of ultra-high stacking. The connection of each stacking layer is realized through the card slot mechanism, ensuring the overall stability of the stacking structure.

[0078] The stacking stability calculation method is used to calculate the critical tipping angle of the stacking structure. The input parameters of this method include the stacking height parameter, chassis width parameter, center of gravity height parameter of the goods, weight parameter of a single-layer Kwikstage, weight parameter of the goods, and gravitational acceleration parameter. The output parameter of this method is the critical tipping angle parameter, which is used to evaluate the stability of the Kwikstage stacking structure.

[0079] When the Kwikstage is in the single-layer use state, the chassis bears the weight of the goods, and the bending beam type load cell detects the center of gravity of the goods to ensure that the goods are at the center position of the Kwikstage. When the Kwikstage is at the first layer of the stacking state, the chassis directly contacts the ground, and the chassis card slots of the upper Kwikstage are accurately docked with the card slots of the top members of this layer. When the Kwikstage is in the middle layer of the stacking state, the chassis card slots are accurately engaged with the card slots of the top members of the lower Kwikstage, and the card slots of the top members are accurately engaged with the chassis card slots of the upper Kwikstage to form a stable connection. When the Kwikstage is at the topmost layer of the stacking state, the chassis card slots are accurately engaged with the card slots of the top members of the lower Kwikstage, and the card slots of the top members are exposed to the external environment.

[0080] When the driverless forklift performs ultra-high stacking operation, first lower the rear of the Kwikstage for positioning, and then adjust the left and right positions of the front according to the center of gravity position of the goods to achieve accurate positioning of adjacent two layers of Kwikstages. After stacking, a five-layer stacking structure is formed, with a total height reaching 6 meters, breaking through the traditional 5-meter line-of-sight blind area limit.

[0081] The following will describe in detail the mathematical models or calculation processes involved in the present invention.

[0082] The calculation method for the positional relationship between the chassis card slots and the top member card slots is used to determine the accurate docking position when stacking the upper and lower layers of Kwikstages, and is specifically expressed as follows:

[0083]

[0084] In the formula, Δ max is the maximum allowable offset between the upper and lower layers of Kwikstages, in mm; L is the chassis length parameter, in mm; W is the chassis width parameter, in mm; θ is the card slot angle parameter, in degrees; δ is the card slot inward movement distance parameter, in mm; H is the column height parameter, in mm.

[0085] Among them, the parameter acquisition method is:

[0086] L is obtained by directly measuring the long side of the chassis main frame. Specifically, a tape measure or precision measuring tool is used to measure the external dimension of the long side of the rectangular structure of the chassis main frame, with a measurement accuracy of 1 mm and a default value of 1350 mm; W is obtained by directly measuring the short side of the chassis main frame. Specifically, a tape measure or precision measuring tool is used to measure the external dimension of the short side of the rectangular structure of the chassis main frame, with a measurement accuracy of 1 mm and a default value of 1150 mm; θ is a design parameter with a default value of 82°. This angle is the optimal slot angle determined through mechanical analysis and experimental verification, which can facilitate stacking operations while providing sufficient clamping strength; δ is a design parameter with a default value of 40 mm. This parameter is determined through finite element analysis and experimental verification and is a key parameter for changing the stress state of the pallet rack; H is obtained by directly measuring the length of the main support member. Specifically, a tape measure or precision measuring tool is used to measure the vertical distance from the upper surface of the chassis to the lower surface of the top member of the main support column, with a measurement accuracy of 1 mm and a default value of 1150 mm.

[0087] This calculation method is based on geometric principles and considers the influence of the slot angle and the inward displacement distance on the stacking accuracy. The cosθ term in the formula represents the projection of the offset in the horizontal direction, and the term (W - 2δ - 2Htan(90° - θ)) / 2 calculates half of the effective clamping width considering the inward displacement of the slot and the height of the column. By introducing the two parameters of the slot angle θ and the inward displacement distance δ, the stress model of the pallet rack changes from a simply supported beam to a cantilever beam, reducing the internal forces of the bending deformation components on the chassis and improving the structural stability.

[0088] The calculation method for the position of the center of gravity of the goods is used to determine the coordinates of the center of gravity of the goods based on the readings of the bending beam type load cells, which is specifically expressed as follows:

[0089]

[0090] In the formula, X cm is the offset coordinate of the center of gravity of the goods in the width direction of the chassis, in mm; Y cm is the offset coordinate of the center of gravity of the goods in the length direction of the chassis, in mm; W is the chassis width parameter, in mm; L is the chassis length parameter, in mm; F FR is the reading of the right front corner sensor, in Newtons; F FL is the reading of the left front corner sensor, in Newtons; F BR is the reading of the right rear corner sensor, in Newtons; F BL is the reading of the left rear corner sensor, in Newtons; F total is the sum of the readings of the four corner sensors, F total = F FR + F FL + F BR + F BL , in Newtons; εx and ε y are error correction terms, with the unit of mm and the value range from -5 to 5 mm.

[0091] Among them, the parameter acquisition method is as follows:

[0092] The acquisition methods of W and L are the same as above; F FR , F FL , F BR , F BL are obtained by real-time acquisition through the bending beam type load cells installed at the four corners of the chassis. Specifically, the electrical signals output by the sensors are converted into digital signals through an amplifier and an analog-to-digital converter, and then converted into weight readings through a calibration curve. The sampling frequency is 10 Hz, and the average value of 5 consecutive readings is taken as the final reading; ε x and ε y are determined through a calibration experiment. Specifically, a standard weight is placed at the center position of the chassis, the readings of the sensors at the four corners are recorded, and the deviation between the calculated center of gravity coordinates and the actual center position is the error correction term.

[0093] This calculation method is based on the principle of moment balance, and calculates the position of the center of gravity of the goods through the reading differences of the sensors at the four corners. In the formula, the term (F FR +F BR )-(F FL +F BL ) represents the moment difference in the width direction, and the term (F FR +F FL )-(F BR +F BL ) represents the moment difference in the length direction. Divide by the total force F total and multiply by half of the corresponding dimension to obtain the center of gravity coordinates. The introduction of the error correction terms ε x and ε y considers the influence of factors such as sensor sensitivity differences and installation errors, and improves the accuracy of the center of gravity position calculation.

[0094] The calculation method of the column load-bearing capacity is used to determine the maximum safe stacking height of the pallet rack, which is specifically expressed as follows:

[0095]

[0096] In the formula, N max is the parameter of the maximum safe stacking layer number, dimensionless; represents the floor function; E is the elastic modulus parameter of the column material, with the unit of megapascal; I is the moment of inertia parameter of the column section, with the unit of the fourth power of mm; F load is the parameter of the full-load weight of a single-layer pallet rack, with the unit of Newton; H is the column height parameter, with the unit of mm; S is the safety factor parameter, dimensionless.

[0097] Among them, the parameter acquisition method is as follows:

[0098] E is obtained according to the steel specification used. For Q235 steel, the value of E is 210000 MPa; I is obtained by calculating the column cross-sectional dimensions. For a rectangular hollow cross-section, where a is the outer side length of the column and t is the wall thickness of the column. For a thickened hollow square pipe of 50×50×2.75, I is approximately 37820 mm to the fourth power; F load is obtained by measuring with a bending beam load cell. Specifically, the maximum design load is placed on the cage stacker, and it is determined by the sum of the sensor readings. The typical value is 18000 Newtons; the acquisition method of H is the same as above; S is determined according to industry standards. Considering factors such as dynamic load effects and material inhomogeneity, the value range is 1.5 to 2.5, and the typical value is 2.0.

[0099] This calculation method is based on the Euler critical load theory and is used to evaluate the buckling stability of the column under compressive loads. In the formula, π 2 The EI term represents the flexural stiffness of the column, and F load ·H 2 The term represents the bending moment effect acting on the column. The ratio of the two divided by the safety factor is rounded down to obtain the maximum safe stacking layer number. This method takes into account the column material properties, geometric dimensions, and load conditions, and reduces the risk brought by calculation uncertainties by introducing the safety factor S, ensuring the safety and reliability of the stacking structure.

[0100] The calculation method for the relationship between the square pipe thickness and the bearing capacity is used to determine the minimum thickness requirement of the chassis square pipe, which is specifically expressed as follows:

[0101]

[0102] In the formula, t min is the minimum thickness parameter of the square pipe, with the unit of mm; a is the side length parameter of the square pipe, with the unit of mm; F load is the load parameter, with the unit of Newton; L is the length parameter of the square pipe, with the unit of mm; S is the safety factor parameter, dimensionless; σ y is the material yield strength parameter, with the unit of MPa.

[0103] Among them, the parameter acquisition method is as follows:

[0104] a is the outer side length of the cross-section of the hollow square pipe, which is obtained by direct measurement. For the chassis main frame, the value of a is 50 mm; F loadis the total weight borne by the rack in the fully loaded state, obtained through theoretical estimation or sensor measurement, with a typical value of 18,000 Newtons; L is the actual length of the hollow square tube, obtained through direct measurement. For the square tube on the long side of the chassis, L is taken as 1350 mm; S is determined according to industry standards. Considering factors such as impact load and material non-uniformity, the value range is from 1.2 to 2.0, and the typical value is 1.5; σ y is obtained according to the steel specification used. For Q235 steel, σ y is taken as 235 MPa.

[0105] This calculation method is based on the bending stress theory in material mechanics and considers the stress distribution of the square tube under bending load. In the formula, the term represents the relative stress level of the square tube under the maximum load, and the minimum wall thickness that meets the strength requirements is obtained by solving the equation. This method considers uncertain factors such as dynamic load and material defects by introducing the safety factor S to ensure the safety and reliability of the square tube under various working conditions.

[0106] The stack stability calculation method is used to calculate the critical tipping angle of the stack structure, which is specifically expressed as follows:

[0107]

[0108] In the formula, φ crit is the critical tipping angle parameter, in degrees; W is the chassis width parameter, in mm; N is the number of stack layers; h i is the height from the center of gravity of the goods on the i-th layer and the rack to the ground, in mm; m i is the mass of the rack and goods on the i-th layer, in kilograms; g is the gravitational acceleration parameter, with a value of 9.8 m / s².

[0109] Among them, the parameter acquisition method is as follows:

[0110] The acquisition method of W is the same as above; N is the actual number of stack layers, usually taken as 5; h i is obtained through calculation. h i = (i - 0.5)·H, where H is the height of a single rack, and i is the layer index, starting from 1; m i includes the self-weight of the rack and the weight of the goods. The self-weight of the rack is obtained by weighing, about 80 kilograms, and the weight of the goods is measured by a bending beam type weighing sensor.

[0111] This calculation method is based on the principle of static equilibrium and considers the change in the position of the center of gravity of the stack structure in the inclined state. The term W / 2 in the formula represents the maximum horizontal distance from the support bottom edge to the projection of the center of gravity, and the denominator term It represents the weighted average center of gravity height of the stacking structure, and the arctangent of the ratio of the two gives the critical tipping angle. By considering the weight distribution and center of gravity height of each layer, this method accurately evaluates the stability of the stacking structure and provides a theoretical basis for safe operation.

[0112] The chassis support structure layout optimization method is used to determine the optimal layout of hollow square tubes and equal - angle steel on the chassis, which is specifically expressed as follows:

[0113] P opt = argmin P (max i，j∈{1，2，...，n-1} |d i - d j |);

[0114] d i = x i+1 - x i , i ∈ {1, 2,..., n - 1};

[0115]

[0116] x i ∈ {0, w1, w1 + w2,..., W - w n};

[0117] In the formula, P opt is the support structure layout scheme parameter, representing the set of positions of each support structure under the optimal layout; P is the set of all possible layout schemes; argmin represents the parameter that makes the objective function take the minimum value; max represents taking the maximum value; d i is the distance between two adjacent support structures; x i is the position coordinate of the i - th support structure; n is the total number of support structures, n = n tube + n angle ; W is the chassis width parameter; w i is the width of the i - th support structure.

[0118] Among them, the method for obtaining the parameters is as follows:

[0119] The method for obtaining W is the same as above; n tube is the hollow square tube quantity parameter, with a value of 9; n angle is the equal - angle steel quantity parameter, with a value of 12; w i is the support structure width, which is 50mm for both hollow square tubes and equal - angle steel.

[0120] This optimization method is based on the principle of uniform distribution, and the goal is to make the distance between all adjacent support structures as uniform as possible. The objective function max i，j∈{1，2，...，n-1} |d i - d j| represents the maximum difference between any two adjacent spacings. Minimizing this difference means a more uniform distribution of the support structure. Constraints Ensure that all support structures are arranged within the width range of the chassis, x i ∈ {0, w1, w1 + w2,..., W - w n} to ensure that the support structures do not overlap. By optimizing the layout of the support structure, this method makes the force on the chassis more uniform, improving the overall strength and stability of the chassis.

[0121] The various calculation methods are interrelated and jointly constitute the theoretical basis of the ultra-high stacking Kwikstage device. The calculation method for the positional relationship between the chassis card slots and the top member card slots ensures stacking accuracy; the calculation method for the position of the center of gravity of the goods provides the ability to monitor the center of gravity; the calculation method for the load-bearing capacity of the columns determines the safe stacking height; the calculation method for the relationship between the square tube thickness and the load-bearing capacity guides material selection; the calculation method for stacking stability evaluates the structural stability; the method for optimizing the layout of the chassis support structure improves the chassis strength. The comprehensive application of these methods enables the Kwikstage device to achieve ultra-high stacking safely and reliably, break through the traditional 5-meter line-of-sight blind area limit, reach a total height of 6 meters, and at the same time ensure structural stability and safety.

[0122] Specifically, the principle of the present invention is: The core technical principle of the present invention lies in achieving precise positioning and stable connection of the Kwikstage ultra-high stacking through precise structural design and mechanical optimization. Traditional Kwikstages mainly rely on simple matching or manual visual assistance during high stacking, while the present invention uses a card slot structure at a specific angle for mechanical optimization, fundamentally changing the force model.

[0123] First, the 82° non-standard angle steel card slot design is based on the shear force transmission principle. This angle can ensure both tight clamping and easy separation operation. When the upper and lower layers of Kwikstages are clamped, due to the angle design, mutual extrusion forces will be generated between the two layers, forming a self-locking effect. The careful calculation of the positional relationship between the top member card slot and the chassis card slot (40 mm inward movement on both sides) changes the force model from a simply supported beam to a cantilever beam. According to the principles of material mechanics, this change reduces the stress concentration of the chassis under the bending member and improves the overall strength of the structure.

[0124] Secondly, the alternating arrangement of the hollow square tubes and equal-angle steels inside the chassis forms a uniformly partitioned grid structure. This design is based on the load dispersion principle, enabling the weight to be evenly transmitted to the entire structure through multi-point support, avoiding local stress concentration. The columns adopt a structure combining main support and auxiliary support. The main support bears the main compressive deformation load, and the auxiliary support forms a triangular stable structure, reducing the buckling risk of the columns and improving the vertical load-bearing capacity.

[0125] The bending beam type load cells in the intelligent monitoring system are arranged at the four corners of the chassis. Based on the center of gravity calculation principle, the center of gravity position of the goods is calculated through the force data at each point to ensure the reasonable placement of the goods. At the same time, the RFID tag or two-dimensional code recognition system realizes the information binding between the cage pallet and the goods, facilitating the intelligent management of the whole process.

[0126] In addition, the present invention also adopts a series of mechanical calculation methods, including position relationship calculation, center of gravity position calculation, bearing capacity calculation, thickness and bearing capacity relationship calculation, stacking stability calculation, and optimization of the chassis support structure layout, etc., to theoretically ensure the scientificity and safety of the cage pallet structure.

[0127] A specific embodiment 1 of the present invention is provided below, and the specific implementation manners of each step in this embodiment 1 are described in detail as follows.

[0128] The specific implementation manner of manufacturing the ultra-high stacking cage pallet device includes the following steps: chassis structure manufacturing step, column structure manufacturing step, top member manufacturing step, precise positioning device manufacturing step, intelligent monitoring system installation step, cage pallet assembly step, and cage pallet performance testing step.

[0129] The chassis structure manufacturing step includes the manufacturing of the chassis main frame and the installation of the internal support structure of the chassis. First, 6 hollow square tubes with a size of 50×50×2 are cut according to the design dimensions, among which 4 tubes with a length of 1350 mm are used for the long sides of the rectangle, and 2 tubes with a length of 1150 mm are used for the short sides of the rectangle. These hollow square tubes are positioned according to the rectangular layout to ensure that the four corners form a 90-degree right angle, and then the hollow square tubes are connected into the chassis main frame by welding. The welds are required to be flat and smooth, and the welding strength is not less than 85% of the strength of the hollow square tube body. The layout of the internal support structure of the chassis is determined by the chassis support structure layout optimization method, and this method is specifically expressed as follows:

[0130] P opt = argmin P (max i，j∈{1，2，...，n-1} |d i -d j |);

[0131] d i = x i+1 -x i , i ∈ {1, 2,..., n - 1};

[0132]

[0133] x i ∈ {0, w1, w1 + w2,..., W - wn};

[0134] In the formula, P optis the support structure layout scheme parameter, which represents the location set of each support structure under the optimal layout; P is the set of all possible layout schemes; d i is the distance between two adjacent support structures; x i is the position coordinate of the i-th support structure; n is the total number of support structures, n=n tube +n angle ; W is the chassis width parameter; w i is the width of the i-th support structure. According to the calculation results, 9 50×50×2 hollow square tubes and 12 50×50×3 equilateral angle steels are cut, and they are evenly arranged alternately and welded on the chassis main frame according to the optimized layout plan. The welding requirements are the same as the main frame welding. Finally, 82° non-standard angle steel slots are installed on the edges of both sides of the chassis, facing the ground side, for precise docking with the upper smart fixing frame. The square tube thickness of the chassis is determined by the calculation method of the relationship between the square tube thickness and the bearing capacity, which is specifically expressed as follows:

[0135]

[0136] In the formula, t min is the minimum thickness parameter of the square tube, in mm; a is the side length parameter of the square tube, in mm; F load is the load parameter, in Newton; L is the length parameter of the square tube, in mm; S is the safety factor parameter, dimensionless; σ y is the material yield strength parameter, in MPa. Through calculation, it is determined that the thickness of the hollow square tube used in the chassis is 2mm, and the thickness of the equilateral angle steel is 3mm, which meets the load-bearing requirements.

[0137] The manufacturing steps of the column structure include the manufacturing of the main support columns and the installation of the auxiliary support columns. First, according to the design height, cut 4 50×50×2.75 thickened hollow square tubes with a length of 1150mm as the main support columns. Reserve the connection points of the auxiliary support columns at the appropriate positions of the main support columns. Then, use fillet welds to weld the 4 main support columns to the four corners of the chassis to ensure that the columns are perpendicular to the plane of the chassis and the verticality error does not exceed 3mm. The weld length shall not be less than 75% of the circumference of the column, and the weld thickness shall not be less than the wall thickness of the column. Next, cut an appropriate amount of 30×30×1.5 hollow square tubes as auxiliary support columns, and weld them between the main support columns according to the design requirements to form a triangular support structure to enhance the overall rigidity and reduce the deformation of the main support columns under pressure. The bearing capacity of the column is determined by the column bearing capacity calculation method, which is specifically expressed as follows:

[0138]

[0139] Where N maxis the parameter of the maximum safe stacking layers, dimensionless; E is the elastic modulus parameter of the column material, with the unit of megapascal; I is the moment of inertia parameter of the column cross-section, with the unit of the fourth power of mm; F load is the parameter of the full-load weight of a single-layer pallet rack, with the unit of Newton; H is the column height parameter, with the unit of mm; S is the safety factor parameter, dimensionless. Through calculation, it is determined that using 50×50×2.75 thickened hollow square tubes as the main support columns can safely support 5 layers of stacking, with a total height of 6 meters.

[0140] The manufacturing steps of the top member include the production of angle steel and the installation of triangular gusset plates. First, cut the angle steel according to the design dimensions, and the length is the same as the length of the chassis, which is 1350 mm. Design and install triangular gusset plates on the inner side of the angle steel to enhance the bending resistance of the angle steel. The angle steel adopts an open design, taking advantage of the instability of the parallelogram, so that the distance between the left and right side members can be appropriately adjusted according to the position of the center of gravity of the goods. Then, weld the angle steel to the top of the 4 main support columns to form the top frame structure. The welding requirements of the weld are the same as those of the column to ensure the connection strength. Finally, install angle slots corresponding to the chassis slots on both sides of the top member, facing upward, for precise docking with the chassis of the upper-layer pallet rack. When the slots of the top member correspond to the slots of the chassis, each side of the slot is moved 40 mm inward, so that the force model of the pallet rack changes from a simply supported beam to a cantilever beam, reducing the internal force of each bending deformation member of the chassis. The positional relationship between the slots of the top member and the slots of the chassis is determined by the calculation method of the positional relationship between the chassis slots and the slots of the top member, which is specifically expressed as follows:

[0141]

[0142] In the formula, Δ max is the maximum allowable offset between the upper and lower layer pallet racks, with the unit of mm; L is the chassis length parameter, with the unit of mm; W is the chassis width parameter, with the unit of mm; θ is the slot angle parameter, with the unit of degree; δ is the slot inward movement distance parameter, with the unit of mm; H is the column height parameter, with the unit of mm. Through calculation, it is determined that the slots of the top member are moved 40 mm inward to form a precise docking structure with the slots of the chassis.

[0143] The manufacturing steps of the precise positioning device include the manufacturing of the chassis card slots and the manufacturing of the top component card slots. The chassis card slots are made of 82° non-standard angle steel and are installed at the two side edges of the chassis, facing the ground side. During the specific manufacturing process, first cut the angle steel to the appropriate length, and then weld the angle steel to the two side edges of the chassis at an angle of 82°. The top component card slots are also made of angle steel and are installed on both sides of the top component, facing upward. Different from the chassis card slots, the top component card slots are moved inward by 40 mm at the corresponding positions. This design improves the structural strength by changing the stress state of the quick-fix frame. The design parameters of the chassis card slots and the top component card slots are determined through experimental verification. The angle of 82° is the optimal angle that facilitates stacking operations while providing sufficient clamping strength, and the inward movement distance of 40 mm is the optimal value determined through finite element analysis and experimental verification.

[0144] The installation steps of the intelligent monitoring system include the installation of load cells and the installation of RFID tags or two-dimensional code identifiers. First, install 2 bending beam load cells at each of the four corners (front, back, left, and right) of the chassis, for a total of 8, to detect the position of the center of gravity of the loaded goods. The load cells are fixed under the chassis using bolt connection methods to ensure stability and reliability. The installation positions of the sensors are optimized to accurately capture the weight distribution of the goods. Then, install RFID tags or two-dimensional code identification identifiers on the outer surface of the quick-fix frame for the binding management of the quick-fix frame and the goods. The identifiers should be installed in obvious positions for easy scanning and identification. Finally, connect the sensors to the control system and set up the data acquisition and processing program. The position of the center of gravity of the goods is determined by the method for calculating the position of the center of gravity of the goods, which is specifically expressed as follows:

[0145]

[0146] In the formula, X cm is the offset coordinate of the center of gravity of the goods in the width direction of the chassis, with the unit of mm; Y cm is the offset coordinate of the center of gravity of the goods in the length direction of the chassis, with the unit of mm; W is the width parameter of the chassis, with the unit of mm; L is the length parameter of the chassis, with the unit of mm; F FR is the reading of the right front corner sensor, with the unit of Newton; F FL is the reading of the left front corner sensor, with the unit of Newton; F BR is the reading of the right rear corner sensor, with the unit of Newton; F BL is the reading of the left rear corner sensor, with the unit of Newton; F total is the sum of the readings of the four corner sensors, with the unit of Newton; ε x and ε y are the error correction terms, with the unit of mm. The position of the center of gravity of the goods is monitored in real time through this method to ensure loading safety.

[0147] The assembly steps of the pallet rack include the final assembly of the chassis, columns, top members, and precise positioning devices. First, check the manufacturing quality of each component to ensure it meets the design requirements. Then, assemble the chassis, columns, and top members together according to the design drawings, and check the firmness of each connection point. Pay special attention to checking the welding quality to ensure there are no defects such as cracks and pores. Next, install the precise positioning device to ensure the angles and positions of the chassis slots and top member slots are accurate. Finally, install the intelligent monitoring system, connect the sensors and control devices to complete the assembly of the entire pallet rack. After the assembly is completed, conduct an appearance inspection to ensure that each component is installed correctly and there are no obvious defects.

[0148] The performance test steps of the pallet rack include load-bearing capacity test, stacking stability test, and monitoring system function test. The load-bearing capacity test is carried out by placing the design load on the pallet rack to detect the deformation of each component and ensure that the structure is still safe and stable under the maximum load. The stacking stability test is carried out by stacking multiple pallet racks to detect the stability of the stacking structure. The stacking stability is evaluated by the stacking stability calculation method, which is specifically expressed as follows:

[0149]

[0150] In the formula, φ crit is the critical tipping angle parameter, in degrees; W is the chassis width parameter, in mm; N is the number of stacking layers; h i is the height from the center of gravity of the goods and the pallet rack on the i-th layer to the ground, in mm; m i is the mass of the pallet rack and the goods on the i-th layer, in kilograms; g is the gravitational acceleration parameter, with a value of 9.8 meters per square second. By calculation, it is determined that the critical tipping angle of the five-layer stacking structure should be greater than 5 degrees to ensure operation safety. The monitoring system function test is carried out by simulating different load conditions to verify the accuracy of sensor data collection and processing and ensure that the system can correctly reflect the position of the center of gravity of the goods.

[0151] After the above manufacturing steps are completed, the usage mode verification of the rack is carried out. When the rack is in the single-layer usage state, the chassis bears the weight of the goods, and the bending beam type weighing sensor detects the center of gravity of the goods to ensure that the goods are at the center position of the rack. When the rack is in the first layer of the stacking state, the chassis is in direct contact with the ground, and the chassis card slots of the upper rack are accurately docked with the card slots of the top members of this layer. When the rack is in the middle layer of the stacking state, the chassis card slots are accurately engaged with the top member card slots of the lower rack, and the top member card slots are accurately engaged with the chassis card slots of the upper rack to form a stable connection. When the rack is in the top layer of the stacking state, the chassis card slots are accurately engaged with the top member card slots of the lower rack, and the top member card slots are exposed to the external environment. When the automated forklift performs the ultra-high stacking operation, first lower the rear of the rack for positioning, and then adjust the left and right positions of the front according to the center of gravity position of the goods to achieve accurate positioning of adjacent two layers of racks. After stacking, a five-layer stacking structure is formed, with a total height reaching 6 meters, breaking through the limitation of the traditional 5-meter line-of-sight blind area.

[0152] Through the above manufacturing steps and performance tests, a rack device for ultra-high stacking is finally manufactured. This device realizes the ultra-high stacking of the rack through a precise positioning device and an intelligent monitoring system, with a total height reaching 6 meters, breaking through the limitation of the traditional 5-meter line-of-sight blind area, and at the same time ensuring the safety and stability of the structure. The design of each component of this device is based on mechanical principles and optimization calculations to ensure that the structure remains stable under the maximum load. The single weight of the rack is about 80 kilograms, and the total weight of the goods and the rack during five-layer stacking is about 9 tons, meeting the strength requirements for ultra-high stacking.

[0153] To better understand and implement the present invention, the following provides Embodiment 2 of a specific application scenario of the present invention: This embodiment provides a rack device for ultra-high stacking applicable to the field of high-density automated warehousing, which can safely and stably achieve stacking at a height of 6 meters and meet the needs of small parts warehousing and logistics. This device has been successfully applied in the automated stereoscopic warehouse of an electronic component manufacturing enterprise, and the processed goods are mainly various electronic components and small components.

[0154] The main frame of this ultra-high stacking rack device is made of Q235A grade steel. The chassis is welded into a rectangular structure by 6 hollow square tubes of 50×50×2, with a length of 1350 mm and a width of 1150 mm. As Figure 1 shown, the overall structure of the rack includes a chassis 1, columns 2, top members 3, a precise positioning device 4, and an intelligent monitoring system 5. The chassis is provided with hollow square tubes and equal-angle steel arranged alternately and evenly. The columns are arranged at the four corners of the chassis and include main support members and auxiliary support members. The top members are arranged at the tops of the columns and adopt an open design. The precise positioning device includes card slot structures arranged at the two side edges of the chassis and the two sides of the top members. The intelligent monitoring system includes bending beam type weighing sensors and RFID tags.

[0155] As shown Figure 2 in the figure, the chassis structure is formed by welding 50×50×2 hollow square tubes to form the main frame 6. Inside, there are 9 50×50×2 hollow square tubes 7 and 12 50×50×3 equal-angle steel bars 8, which are evenly and alternately arranged and welded to the main frame to form a grid-like support structure. The equal-angle steel bars evenly divide the chassis into 13 areas, facilitating the adjustment of the center of gravity when placing goods. At the edges on both sides of the chassis, chassis card slots 16 made of 82° non-standard angle steel are installed, facing the ground side. At each of the four corners of the chassis, 2 bending beam type load cells 10 are installed, a total of 8, for monitoring the position of the center of gravity of the goods. The specific parameters of the main frame of the chassis are shown in Table 1:

[0156] Table 1 Parameters of the main frame of the chassis

[0157] Structural component Material specification Quantity Dimensions (mm) Layout method Long-side square tube 50×50×2 4 pieces 1350 Rectangular long side Short-side square tube 50×50×2 2 pieces 1150 Rectangular short side Internal square tube 50×50×2 9 pieces 1150 Uniformly arranged alternately Equal-angle steel 50×50×3 12 pieces 1150 Uniformly arranged alternately 82° card slot Non-standard angle steel 2 pieces 1350 Both edges of the chassis

[0158] As shown Figure 3 in the figure, the column structure includes 4 50×50×2.75 thickened hollow square tubes as the main support columns 11 and several 30×30×1.5 hollow square tubes as the auxiliary support columns 12. The height of the main support columns is 1150 mm. The columns and the chassis are connected by fillet welds, and the weld length is not less than 75% of the perimeter of the columns. The auxiliary support columns are fixed between the main support columns by welding to form a triangular support structure, reducing the deformation of the main support columns under pressure. According to the calculation method of the bearing capacity of the columns, when the safety factor is taken as 2.0, the maximum allowable safe stacking layer number of this structure is 5 layers. The specific parameters of the column structure are shown in Table 2:

[0159] Table 2 Parameters of the column structure

[0160] Structural component Material specification Quantity Height (mm) Installation position Main support column 50×50×2.75 4 pieces 1150 Four corners of the chassis Auxiliary support column 30×30×1.5 12 pieces Unequal length Between the main columns Triangular rib plate Steel plate with a thickness of 3mm 8 pieces 150×150 Connection between the main column and the chassis

[0161] As shown Figure 4 in the figure, the top member is made of angle steel. The length of the angle steel is the same as the length of the chassis, which is 1350 mm. Triangular gusset plates 13 are built-in to enhance the bending resistance. The top member adopts an open design 14. Utilizing the instability of the parallelogram, the distance between the left and right side members can be appropriately adjusted according to the position of the center of gravity of the goods. Angle card slots corresponding to the chassis card slots are installed on both sides of the top member, facing upward, for precise docking with the chassis of the upper layer of the QuickFix rack. When the card slots of the top member and the chassis are corresponding, each side of the card slot is moved 40 mm inward, changing the force model of the QuickFix rack from a simply supported beam to a cantilever beam.

[0162] As shown Figure 5As shown in the figure, the core of the precise positioning device is the design of the chassis slot 16 and the top member slot 17. The chassis slot is made of 82° non-standard angle steel, and the top member slot moves 40 mm inward when corresponding to the chassis slot. Through the calculation method of the positional relationship between the chassis slot and the top member slot, it is calculated that when the chassis width is 1150 mm, the slot angle is 82°, the slot inward movement distance is 40 mm, and the column height is 1150 mm, the maximum allowable offset between the upper and lower layer Cage Pallets is 35 mm, which can meet the stacking accuracy requirements of automated forklifts. The parameters of the precise positioning device are shown in Table 3:

[0163] Table 3 Parameters of the Precise Positioning Device

[0164] Structural component Angle (°) Inner shift distance (mm) Maximum allowable offset (mm) Function effect Chassis card slot 82 0 35 Docking with the upper layer Top component card slot 82 40 35 Docking with the lower layer

[0165] As Figure 6 shown in the figure, the intelligent monitoring system includes 8 bending beam type load cells 10 and RFID tags. The bending beam type load cells are distributed at the four corners of the chassis, 2 at each corner, for detecting the center of gravity position of the loaded goods. The sensor model is HBMPW10, with a range of 0 - 2000 kg and an accuracy of 0.02% F.S. The RFID tags are set on the outer surface of the Cage Pallet for realizing the binding management between the Cage Pallet and the goods. According to the calculation method of the center of gravity position of the goods, the system can calculate the center of gravity coordinates of the goods in real time and issue an alarm when the offset exceeds the set threshold. The parameters of the intelligent monitoring system are shown in Table 4:

[0166] Table 4 Parameters of the Intelligent Monitoring System

[0167] Equipment name Model specification Quantity Installation position Technical parameters Bending beam type load cell HBM PW10 8 pieces 2 pieces at each of the four corners of the chassis Range 0 - 2000kg, accuracy 0.02%F.S RFID tag UHF passive type 4 pieces Four sides of the cage Reading distance 3m, storage capacity 96bit Data processing unit Custom development 1 set Inside the chassis Sampling frequency 10Hz, wireless transmission

[0168] As Figure 7 shown in the figure, the stacking structure of the Cage Pallet can reach five - layer stacking 21, with a total height of 6 meters, breaking through the limitation of the traditional 5 - meter line - of - sight blind area. Each layer of the Cage Pallet is stably connected through the precise positioning device to form an integral structure. The single weight of the Cage Pallet is about 80 kg, the full - load weight is about 380 kg, and the total weight during five - layer stacking is about 1900 kg. Through the calculation method of stacking stability, the critical tipping angle of the five - layer stacking structure is 8.7 degrees, which is greater than the safety threshold of 5 degrees, ensuring the structural stability. The parameters of the stacking structure are shown in Table 5:

[0169] Table 5 Parameters of the Stacking Structure

[0170] Stacking layers Total height (m) Total weight (kg) Critical tipping angle (°) Load capacity (%) 1 1.2 380 25.3 100 2 2.4 760 18.5 95 3 3.6 1140 14.2 90 4 4.8 1520 10.8 85 5 6.0 1900 8.7 80

[0171] The cage pallet has different working modes under different usage states. When used in the single-layer state 22, the chassis bears the weight of the goods, and the sensor detects the center of gravity of the goods; when stacking the first layer 23, the chassis directly contacts the ground, and the chassis card slots of the upper cage pallet are accurately docked with the card slots of the top components of this layer; when stacking the middle layer 24, the chassis card slots are accurately engaged with the card slots of the top components of the lower layer, and the card slots of the top components are accurately engaged with the chassis card slots of the upper layer; when stacking the topmost layer 25, the chassis card slots are accurately engaged with the card slots of the top components of the lower layer, and the card slots of the top components are exposed to the external environment. The working parameters under different usage states are shown in Table 6:

[0172] Table 6 Working Parameter Table under Different Usage States

[0173] Usage status Chassis card slot Top card slot Center of gravity offset limit (mm) Monitoring requirements Single-layer use Not enabled Not enabled ±100 Center of gravity of goods First layer of stacking Not enabled Enabled ±75 Total load distribution Middle layer of stacking Enabled Enabled ±50 Connection stability Top layer of stacking Enabled Not enabled ±30 Overall stability

[0174] The force-bearing model of the cage pallet is changed due to the inward movement design of the card slots. In the traditional design, the card slots of the top components of the cage pallet and the chassis card slots are on the same vertical line 26, forming a simply supported beam structure; in the present invention, the card slots of the top components move inward by 40 mm 27, making the force-bearing model become a cantilever beam structure, reducing the internal force of each bending deformation component of the chassis, and improving the overall structural strength. The parameter comparison of the force-bearing models is shown in Table 7:

[0175] Table 7 Parameter Comparison Table of Force-bearing Models

[0176] Force model Card slot position Maximum chassis deformation (mm) Safe load (kg) Structural features Simply supported beam Vertically aligned 8.5 320 Large deformation, low load-bearing Cantilever beam Inner shift 40mm 3.2 380 Small deformation, high load-bearing

[0177] The manufacturing and installation process of the ultra-high stacking cage pallet device includes chassis manufacturing, column manufacturing, top component manufacturing, precise positioning device installation, intelligent monitoring system integration, and final assembly and testing. During the manufacturing process, standard welding technology is used, and the welds are required to be flat and smooth, and the strength is not less than 85% of the base material. Anti-corrosion treatment and spraying process are carried out on the surfaces of all components, and the color is blue, improving the corrosion resistance and aesthetics. The device has been running in the actual usage environment for more than 5000 hours, without structural failures, the accuracy rate of center of gravity monitoring reaches 98.5%, and the stacking positioning accuracy is better than ±15 mm.

[0178] The traditional stacking device for racking relies mainly on gravity and friction to achieve stacking stability, lacking a precise positioning mechanism. The stacking height is generally limited within 4 - 5 meters. The main problems include: low stacking positioning accuracy, usually with a deviation of ±50mm; inability to monitor the center of gravity position of goods, prone to tipping accidents; the force-bearing structure is a simply supported beam, with large chassis deformation; the stacking height is restricted and cannot break through the 5-meter line-of-sight blind area limit. The present invention solves these problems through innovative designs: adopting an 82° non-standard angle steel slot for precise positioning, with the positioning accuracy improved to ±15mm; integrating a bending beam type weighing sensor to monitor the center of gravity position of goods in real time and avoid tipping risks; the slot of the top member is shifted inwards by 40mm, changing the force-bearing model and reducing the chassis deformation by 62%; overall design optimization enables stacking at a height of 6 meters, breaking through the traditional 5-meter line-of-sight blind area limit. These innovations have achieved a breakthrough in the field of warehouse automation for racking devices, which is particularly suitable for stacking and storing high-density, small parts, improving the utilization rate of warehouse space and operation safety.

[0179] It should be noted that the detailed explanations of the variables involved in the present invention are shown in Table 10 below.

[0180] Table 10 Variable Explanation Table

[0181]

[0182]

[0183] As described above, it is only the specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present invention can easily think of changes or substitutions, which should all be covered within the protection scope of the present invention.

Claims

1. A cage rack device for ultra-high stacking, comprising a chassis, columns, a top member, a precise positioning device, and an intelligent monitoring system, characterized in that, The chassis is set as a rectangular structure, and the columns are arranged at the four corners of the chassis; the top member is set at the top of the columns and adopts an open design; the precise positioning device includes slots arranged at the two side edges of the chassis and facing the ground side, and slots arranged on both sides of the top member and facing upward; when the slots of the top member correspond to the slots of the chassis, move both sides of the slots inward by a certain distance, so that the force model of the pallet rack changes from a simply supported beam to a cantilever beam, reducing the internal force of each bending deformation member of the chassis; the intelligent monitoring system includes bending beam type weighing sensors and identification marks, which are used to detect the center of gravity position of the loaded goods and realize the binding management of the pallet rack and the goods.

2. The cage rack device for ultra-high stacking according to claim 1, wherein The chassis is welded by hollow square tubes to form the main frame. Hollow square tubes are arranged along the long side of the rectangle, and hollow square tubes are arranged along the short side of the rectangle; hollow square tubes and equal-angle steel are arranged alternately from left to right in the main frame of the chassis and welded on the main frame of the chassis; the equal-angle steel evenly divides the chassis, which is used to adjust the center of gravity of the goods and make the force on the chassis uniform.

3. The cage pallet device for ultra-high stacking according to claim 2, characterized in that, The column includes a thickened hollow square tube as the main support member and a hollow square tube as the auxiliary support member; the main support member bears the main compressive deformation load, and the auxiliary support member reduces the internal force borne by the column.

4. The cage rack device for ultra-high stacking according to claim 3, characterized in that, The left and right sides of the top member are made of angle steel, and triangular rib plates are built in the angle steel; the top member adopts an open design, and using the instability of the parallelogram, the distance between the left and right side members can be adjusted according to the center of gravity position of the goods.

5. The cage rack device for ultra-high stacking according to claim 4, characterized in that In the precise positioning device, the slots at the two side edges of the chassis are set as non-standard angle steel slots and face the ground side; the slots on both sides of the top member face upward and are set as corresponding angle slots.

6. The cage rack device for ultra-high stacking according to claim 5, characterized in that, The bending beam type weighing sensors are arranged at the four corners of the front, back, left and right of the chassis, which are used to detect the center of gravity position of the loaded goods; the identification marks are arranged on the outer surface of the pallet rack, which are used to realize the binding management of the pallet rack and the goods.

7. The cage rack device for super-high stacking according to claim 6, characterized in that, When the pallet rack is in the single-layer use state, the chassis bears the weight of the goods, and the bending beam type weighing sensors detect the center of gravity of the goods to ensure that the goods are at the center position of the pallet rack; when the pallet rack is in the first layer of the stacking state, the chassis directly contacts the ground, and the chassis slots of the upper pallet rack are accurately docked with the top member slots of this layer; when the pallet rack is in the middle layer of the stacking state, the chassis slots are accurately engaged with the top member slots of the lower pallet rack, and the top member slots are accurately engaged with the chassis slots of the upper pallet rack to form a stable connection.

8. The cage rack device for ultra-high stacking according to claim 7, characterized in that, It also includes determining the optimal layout of the hollow square tubes and equal-angle steel on the chassis by using the chassis support structure layout optimization method. The input parameters include the chassis width parameter, the hollow square tube width parameter, the equal-angle steel width parameter, the hollow square tube quantity parameter, the equal-angle steel quantity parameter, and the spacing variance threshold parameter, and the output parameter is the support structure layout scheme parameter.

9. The cage rack device for super-high stacking according to claim 8, characterized in that, It also includes determining the maximum safe stacking height of the pallet rack by using the column bearing capacity calculation method. The input parameters include the elastic modulus parameter of the column material, the moment of inertia parameter of the column section, the column height parameter, the full-load weight parameter of the single-layer pallet rack, and the safety factor parameter, and the output parameter is the maximum safe stacking layer number parameter.

10. The cage rack device for ultra-high stacking according to claim 9, characterized in that, It also includes calculating the critical tipping angle of the stacking structure by using the stacking stability calculation method. The input parameters include the stacking height parameter, the chassis width parameter, the center of gravity height parameter of the goods, the weight parameter of a single-layer cage, the weight parameter of the goods, and the gravitational acceleration parameter. The output parameter is the critical tipping angle parameter.

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