Prefabricated rack structure and assembly method therefor

Abstract

The present invention relates to a prefabricated rack structure and an assembly method therefor, which can reduce design costs through standardization and allow easy assembly, the rack structure comprising: posts arranged in a vertical direction; post bases coupled respectively to the tops and bottoms of the posts; horizontal bracings coupled to the posts at positions adjacent to respective post bases; a plurality of load beams coupled to the posts at positions between the horizontal bracings; and diagonal bracings coupled diagonally to the posts in a truss structure between a horizontal bracing and a load beam and between load beams, wherein each post and / or load beam has a pipe embedded therein so as to reinforce the internal structure, and the components are standardized to improve quality.

Description

Prefabricated rack structure and assembly method thereof

[0001] The present invention relates to a rack structure capable of providing a rack in a modular fashion and a method of assembling the same. In particular, it relates to a modular rack structure and a method of assembling the same that can reduce manufacturing costs by simplifying the manufacturing process for racks used to load and store goods in logistics warehouses, reduce design costs through standardization, reduce logistics costs due to volume reduction, and reduce installation costs due to a structure that is easy to assemble.

[0002] Generally, a logistics warehouse is a storage facility for temporarily or for a long period storing all daily goods, such as various foodstuffs, beverages, clothing, home appliances, miscellaneous goods, and industrial supplies, that are mass-produced at factories or production sites before being delivered to consumers. To facilitate the placement of products within the warehouse, as well as efficient inbound, outbound, and inventory management, rack structures with standardized widths and heights for storing goods are installed.

[0003] Meanwhile, to manufacture such rack structures, multiple frames are first produced at the production site according to the specifications of the installation location within the logistics warehouse and transported to the site (warehouse). Subsequently, the individual frames are connected and installed through welding or other processes. In other words, prefabricated racks used for loading or storage in logistics warehouses are designed and manufactured with different sizes and shapes depending on the size, weight, and intended use of the goods being loaded.

[0004] The manufacturing methods of these prefabricated racks are broadly classified into welding and assembly methods.

[0005] First, the assembly method involves rolling-forming posts into C- or omega shapes and punching holes at regular intervals, utilizing these holes to connect horizontal bracing, diagonal bracing, and load beams. In the production of conventional modular racks, posts are made by bending steel plates using mechanical pressure via rolling dies and punching holes; however, for heavy loads, the steel plates must be thick, making it impossible to manufacture beyond a certain size. Additionally, the uniform spacing of the holes limits the ability to adjust the desired height. Furthermore, the evenly spaced holes lead to a decrease in structural strength. Since the products are manufactured in omega or C-shapes, they also present structural weaknesses, requiring fastening on three sides or fewer.

[0006] In the case of the aforementioned welded racks, standard pipes are used to manufacture them through cutting, welding, and finishing painting processes according to the shape; however, welding deformation makes it difficult to produce them with precise dimensions. Furthermore, the large volume and heavy weight of the welded product make it difficult to handle in general painting factories, and additional processing is required due to dents or scratches occurring during transportation. Since the product is transported in a bulky state after welding, its low weight relative to its volume leads to increased logistics costs for containers or cargo vehicles. Additionally, problems arise where the product must be discarded if changes occur during on-site installation or design modifications, or if its intended use changes during operation.

[0007] An example of a technology for solving these problems is disclosed in the following patent documents 1 to 3, etc.

[0008] For example, Patent Document 1 (Republic of Korea Registered Patent Publication No. 10-2509416, registered on March 8, 2023) discloses a rack structure and a construction method in which a plurality of posts formed by a pair of left and right vertical frames, which are positioned spaced apart at a predetermined distance from each other and firmly supported by bracing, are positioned from the front to the rear at a predetermined distance, a plurality of rack unit assemblies are positioned parallel to each other to form a plurality of passages, the upper ends of the posts located on the left and right straight lines of the plurality of rack unit assemblies are simultaneously inserted into the indentation of a channel steel section and fixed together, a plurality of square steel pipes are fixed parallel to the steel section perpendicularly, and plywood is placed on the plurality of square steel pipes.

[0009] In addition, Patent Document 2 (Republic of Korea Registered Patent Publication No. 10-1438793, registered September 1, 2014) describes an upper frame having a male mounting part formed with a first screw hole, a lower frame having a female mounting part formed with a second screw hole, a column frame installed between the upper frame and the lower frame, wherein a female mounting part is formed at the top that is coupled to the male mounting part and has a third screw hole formed therein communicating with the first screw hole, and a male mounting part is formed at the bottom that is coupled to the female mounting part and has a fourth screw hole formed therein communicating with the second screw hole, a column frame having a bald head and a screw inserted into the first screw hole and the third screw hole to combine the column frame and the upper frame, or inserted into the second screw hole and the fourth screw hole to combine the column frame and the lower frame, and the upper frame and the column and the column to cover the first screw hole and the second screw hole. An assembled rack mount is disclosed, comprising a first reinforcing block that is screw-coupled to each frame.

[0010] Meanwhile, Patent Document 3 (Republic of Korea Registered Patent Publication No. 10-2586373, registered on October 4, 2023) discloses a pipe rack assembly method comprising the steps of: moving a first mounting bracket, on which at least one spool is fixedly mounted on an upper surface, to a preset position; lifting the first mounting bracket to a preset height using a lifting device; moving the second mounting bracket, on which at least one spool is fixedly mounted, to the preset position so that the second mounting bracket is positioned vertically and vertically with respect to the first mounting bracket, forming a predetermined distance from the first mounting bracket; and guiding a side rack, which is equipped with a horizontal girder at a position corresponding to the first mounting bracket and the second mounting bracket, to be side-coupled to the first mounting bracket and the second mounting bracket using a sliding device.

[0011] Patent Document 1, as described above, discloses a technology that can significantly reduce material and labor costs by eliminating the need to install metal floor plates during upper construction, Patent Document 2 discloses a technology that can be recycled by varying the height, and Patent Document 3 discloses a technology that can improve safety and productivity by minimizing damage to the spool and eliminating high-altitude work. However, the problems regarding increased welding costs incurred during the process, increased costs in the painting process due to increased volume, and increased logistics and packaging costs due to the volume of the product were not disclosed.

[0012] In other words, logistics racks are a core component of warehouse automation in industrial settings. Since the size of goods varies by industry and production process, racks must be optimized to fit the factory or warehouse area due to space constraints. Furthermore, most factories equipped with automated lines utilize robots or automated equipment for high-speed loading and unloading within optimal spaces; therefore, precise tolerances and optimal spatial arrangements must be secured between each loading area. Additionally, when product models are changed in accordance with industrial trends, new racks are traditionally manufactured, incurring costs. Instead, existing racks should be recycled for installation at minimal cost, and they must be freely adjustable regardless of load or size. Consequently, it is necessary to manufacture rack systems that eliminate unnecessary processes, reduce logistics costs, meet quality requirements, and facilitate easy maintenance and repair.

[0013] Meanwhile, since racks are designed for different factory environments and varying sizes and weights of cargo, designers must find pipes of suitable specifications and connection methods to redesign each time, which increases design costs and incurs rework costs due to design errors. Therefore, it is necessary to standardize manufacturing by designing with standardized and verified materials to ensure stable quality and cost reduction.

[0014] The objective of the present invention is to solve the problems described above by providing a prefabricated rack structure and a method for assembling the same, which compensates for the disadvantages of conventional Omega racks and improves upon the problems of welded racks to reduce manufacturing and logistics costs, shortens design time to facilitate modifications during on-site installation, and allows for easy disassembly, movement, and modification during use.

[0015] Another objective of the present invention is to provide a prefabricated rack structure and a method for assembling the same, applicable in small areas such as pallet racks, arm racks, heavy-duty racks, light-duty racks, stacking racks, sliding racks, drive-in racks, and mold racks used in logistics warehouses, and applicable in large areas such as connecting vertical frames and horizontal frames via welding.

[0016] Another objective of the present invention is to provide a prefabricated rack structure and a method of assembling the same that can be applied equally even if the size and weight of the cargo change, by simplifying the fastening method using standardized accessories and standardizing the dimensions and thickness of the pipes used for vertical and horizontal members to only one standard.

[0017] Another objective of the present invention is to provide a prefabricated rack structure and a method of assembling the same that are universally applicable even when the size and weight of the cargo vary, by using the same material and size for the external dimensions, inserting a reinforcing pipe inside the pipe, and filling the square pipe with a product having compressive strength, such as cement mortar or epoxy mortar, according to the load of the cargo.

[0018] Another objective of the present invention is to provide a prefabricated rack structure and a method for assembling the same, which can produce precise products by preventing errors caused by thermal deformation due to welding, satisfy precision requirements, and provide a structure that can be easily manufactured by a layperson without the need for a skilled welder, thereby improving quality, shortening delivery times, and reducing costs.

[0019] Another objective of the present invention is to provide a prefabricated rack structure and a method for assembling the same that enables rapid response to various variables occurring on-site and, depending on the situation, allows for the relocation of a minimum amount of equipment to a local country, thereby resolving issues regarding customs duties or logistics costs.

[0020] To achieve the above objective, the prefabricated rack structure according to the present invention comprises a post arranged in a vertical direction, a post base respectively coupled to the upper and lower parts of the post, a horizontal bracing coupled to the post adjacent to the post base, a plurality of load beams coupled to the post between the horizontal bracing, and diagonal bracing coupled in a truss structure diagonally to the post between the horizontal bracing and the load beams and between the plurality of load beams, and is characterized in that a pipe is embedded inside the post and / or the load beam.

[0021] In addition, the prefabricated rack structure according to the present invention is characterized in that a filler material is filled inside the post.

[0022] In addition, in the prefabricated rack structure according to the present invention, the filler is characterized as being one of concrete, cement mortar, epoxy mortar, or resin material.

[0023] In addition, in the prefabricated rack structure according to the present invention, the post and / or the load beam is formed in a square shape, and the pipe is formed in a circular shape.

[0024] In addition, the prefabricated rack structure according to the present invention further comprises a post clamp that is mounted inside the post and into which the pipe is inserted, wherein the post clamp comprises a supporting projection provided to contact the inner wall of each post and a connecting portion provided between the supporting projections.

[0025] In addition, the prefabricated rack structure according to the present invention further includes a fastening clamp coupled to the outside of the post through a bolt hole of the post, wherein the fastening clamp is provided with a plurality of fastening protrusions, and the fastening clamp is coupled to the post and the post clamp through a fastening groove.

[0026] In addition, the prefabricated rack structure according to the present invention further comprises a connector connecting the horizontal bracing, the diagonal bracing and / or the load beam and the fastening clamp, wherein the fastening clamp is provided in a pair and the connector is coupled between the fastening projections of the pair of fastening clamps.

[0027] Furthermore, in the prefabricated rack structure according to the present invention, the structure further includes an extension portion provided to extend the length of the post, wherein the extension portion includes a connecting plate that connects the upper post and the lower post through a bolt hole provided in the post, wherein an upper post clamp and a lower post clamp are respectively mounted inside the upper post and the lower post, and wherein the upper post clamp and the lower post clamp are fastened at a certain distance by means of a connecting bolt through a connecting member provided in the connection portion, and wherein the upper post and the lower post are connected by bolting the bolt insertion holes of the upper post clamp and the lower post clamp, the bolt holes provided in the upper post and the lower post, and the connecting plate.

[0028] In addition, in the prefabricated rack structure according to the present invention, the load beam comprises a first load beam and a second load beam, and each of the first load beam and the second load beam has a load beam clamp built into it to maintain a constant clearance of the pipe, and the first load beam and the second load beam are joined by a pair of connecting bars, and the pair of connecting bars are inserted into and joined to the connector.

[0029] In addition, to achieve the above objective, the assembly method of a prefabricated rack structure according to the present invention comprises the steps of: (a) providing a post, a post base, a horizontal bracing, a load beam, a diagonal bracing, a pipe embedded inside the post and the load beam, a fastening clamp, a post clamp, and a connector; (b) inserting the pipe into the post clamp and embedding the pipe inside the post and / or the load beam; (c) combining the post, the post clamp, and the fastening clamp; (d) combining the post base to the upper and lower parts of the post; and (e) combining the fastening clamp with the horizontal bracing, the load beam, and / or the diagonal bracing through the connector.

[0030] As described above, according to the prefabricated rack structure and assembly method of the present invention, by embedding pipes inside the posts and / or load beams, the effect of improving quality through the standardization of parts is obtained by reinforcing the internal structure while maintaining the same external appearance of the product.

[0031] In addition, according to the prefabricated rack structure and assembly method of the present invention, even if the weight of the cargo increases, the size of the posts is applied identically and the internal strength is increased, thereby achieving the effect of maximizing the storage efficiency of the logistics warehouse.

[0032] Furthermore, according to the prefabricated rack structure and assembly method of the present invention, design, manufacturing, modification, and dismantling can be resolved quickly and precisely according to the size and weight of various cargoes, and the effect of reducing costs by minimizing processes and optimizing logistics is also obtained.

[0033] In addition, according to the prefabricated rack structure and assembly method of the present invention, the effect of maintaining stable quality is obtained by resolving problems caused by welding deformation and deformation resulting from welding stress.

[0034] Furthermore, according to the prefabricated rack structure and assembly method of the present invention, even a simple skilled worker can easily manufacture it without welding, and the manufacturing process is minimized to reduce manufacturing costs, the area of ​​the pipe is reduced to reduce painting costs, and raw material costs are reduced by manufacturing it in standardized specifications.

[0035] FIG. 1 is a perspective view showing an example of a prefabricated rack structure having a plurality of racks combined according to the present invention.

[0036] FIG. 2 is a perspective view of the basic structure of the rack shown in FIG. 1.

[0037] FIG. 3 is an enlarged view of part A shown in FIG. 2,

[0038] FIG. 4 is a drawing showing the internal state with some structures, such as posts and load beams, removed from the structure shown in FIG. 3.

[0039] FIG. 5 is an exploded perspective view illustrating the combined state of the post, horizontal bracing, and load beam shown in FIG. 3.

[0040] FIG. 6 is a perspective view of the fastening clamp shown in FIG. 5,

[0041] FIG. 7 is a perspective view of the combined connector shown in FIG. 5,

[0042] FIG. 8 is a perspective view of the post clamp shown in FIG. 5,

[0043] FIG. 9 is an exploded perspective view for explaining the combined state of a post, pipe, and load beam by removing some structures, such as a post and a load beam, from the structure shown in FIG. 2.

[0044] FIG. 10 is a perspective view of the load beam connector shown in FIG. 9,

[0045] FIG. 11 is an exploded perspective view of the post base shown in FIG. 2,

[0046] FIG. 12 is an exploded perspective view of the extension shown in FIG. 2.

[0047] The above and other objects and novel features of the present invention will become more apparent from the description in this specification and the accompanying drawings.

[0048] The size and thickness of each component shown in the description and drawings of the present invention are depicted arbitrarily for convenience of explanation, and therefore the present invention is not necessarily limited to what is illustrated. Additionally, thicknesses, etc., may be enlarged in the drawings to clearly represent each component. Furthermore, when a part such as a region is described as being "above" or "on" another part, this includes not only the case where it is "immediately above" another part, but also the case where there is another part in between. Conversely, when a part is described as being "immediately above" another part, it means that there is no other part in between. Also, being described as being "above" or "on" a reference part means being located above or below the reference part, and does not necessarily mean being located "above" or "on" facing the opposite direction of gravity.

[0049] Meanwhile, in the description of the invention, when it is stated that a certain part "includes" a certain component, this means that, unless specifically stated otherwise, it does not exclude other components but may include additional components.

[0050] As used herein, the terms “part,” “module,” or “part” may consist of a plurality of mechanical components (parts) to perform at least one function or operation, and terms such as “first,” “second,” etc. may be used to describe various components, but said components should not be limited by said terms. These terms are used solely for the purpose of distinguishing one component from another. For example, without departing from the scope of the present invention, the first component may be named the second component, and similarly, the second component may be named the first component. The term “and / or” includes a combination of a plurality of related described items or any of a plurality of related described items.

[0051] Meanwhile, as a term used herein, "rack structure" refers to a state in which a first rack to N (where N is an integer of 2 or more) are combined into one, and the first rack is formed by arranging a first post, a second post, a third post, and a fourth post in a square shape, and the third post and the fourth post of the first rack may be provided in a structure such that they are used as the first post and the second post of the second rack.

[0052] Hereinafter, an embodiment according to the present invention will be described with reference to the drawings.

[0053] FIG. 1 is a perspective view showing an example of a prefabricated rack structure in which a plurality of racks are combined according to the present invention, and FIG. 2 is a perspective view of the basic structure of the rack shown in FIG. 1.

[0054] FIG. 1 illustrates a structure of a rack structure according to the present invention in which the first to fourth racks are combined, but it is not limited thereto. It may be composed of only the first rack, or composed of only the first rack and the second rack, or a structure composed of multiple racks such as a structure composed of the first to third racks, or a structure composed of the first to fifth racks, etc. That is, the rack structure according to the present invention is applicable to a standalone rack or a connected rack. Also, FIG. 1 illustrates a structure in which multiple racks are combined in the horizontal direction, but it is not limited thereto. It may also be provided as a structure in which multiple racks are combined in the vertical direction.

[0055] For convenience of explanation, in the following description, the structure of the first rack according to the present invention is described as the basic structure of the prefabricated rack (100) as shown in FIG. 2, but is not limited thereto.

[0056] As shown in FIGS. 1 and 2, the prefabricated rack (100) of the rack structure according to the present invention may include first and second posts (110, 110') arranged in a vertical direction, a post base (130) respectively coupled to the upper and lower parts of the first and second posts (110, 110'), a horizontal bracing (140) coupled between the first post (110) and the second post (110') adjacent to the post base (130), a plurality of load beams (150) coupled between the first post (110) and the second post (110') between the horizontal bracing (140), and a plurality of diagonal bracing (160) coupled diagonally to the posts between the horizontal bracing (140) and the load beams (150) and between the plurality of load beams (150).

[0057] In addition, the height of the post according to the present invention can be extended by providing an extension part (170) as shown in FIG. 2. Meanwhile, FIG. 2 shows a structure provided with four diagonal bracing (160) and a load beam (150), but it is not limited thereto, and when the post is extended by the extension part (170), five or more diagonal bracing (160) and a load beam (150) may be provided.

[0058] In the frame structure of the prefabricated rack (100) according to the present invention, the frame of the post is provided according to only one standard, the frame of the bracing is provided according to only one standard, and the frame of the load beam is provided according to only one standard, so mass production is possible and accordingly, manufacturing costs can be reduced.

[0059] Additionally, the first and second posts (110, 110') and / or the load beam (150) may be provided in a square shape, and for example, the posts may be composed only of 7575 3T pipes, 3060 2T pipes, and 3030 2T square pipes, but the specifications of the pipes may be applied differently depending on the industry or process.

[0060] Next, the combined structure of the first post (110) and second post (110'), post base (130), horizontal bracing (140), load beam (150), and diagonal bracing (160) will be described with reference to FIGS. 3 to 5. Additionally, since the combined structure of the first post (110), post base (130), horizontal bracing (140), load beam (150), and diagonal bracing (160), and the combined structure of the second post (110') and post base (130), horizontal bracing (140), load beam (150), and diagonal bracing (160) can be implemented in the same way, the following description mainly describes the combined structure of the first post (110), post base (130), horizontal bracing (140), load beam (150), and diagonal bracing (160), and the first post (110) and the second post (110') may be described simply as 'posts'. Additionally, the load beam (150) may be composed of a first load beam (151) and a second load beam (151') arranged to maintain a certain distance from each other by means of a connecting bar (152), as shown in FIGS. 2 and 3.

[0061] FIG. 3 is an enlarged view of part A shown in FIG. 2, showing the combined state of the first post and the horizontal bracing; FIG. 4 is a drawing showing the internal state with some structures, such as the post and the load beam, removed from the structure shown in FIG. 3; and FIG. 5 is an exploded perspective view to explain the combined state of the post, the horizontal bracing, and the load beam shown in FIG. 3.

[0062] As illustrated in FIGS. 3 and 4, the first post (110) and the horizontal bracing (140) can be joined by a fastening clamp (180) and a bracing and load beam combined connector (190). Also, as illustrated in FIG. 3, the first post (110), the first load beam (151), and the second load beam (151') can be joined through the bracing and load beam combined connector (190).

[0063] Additionally, as shown in FIGS. 4 and 5, a post pipe (111) is embedded inside the first post (110). The first post (110) may be formed in a square shape as shown in FIG. 3, and the post pipe (111) may be formed in a circular shape as shown in FIG. 4. The post pipe (111) may be maintained inside the first post (110) while maintaining a certain gap, and a filler material may be filled in the gap. In addition, any one of concrete, cement mortar, or epoxy mortar may be applied as the filler material.

[0064] That is, in the prefabricated rack structure according to the present invention, when only the first post (110) is connected without a separate internal structure, light cargo can be loaded, and when a circular post pipe (111) is reinforced inside the first post (110), heavy cargo can be loaded. In addition, as described above, if a circular post pipe (111) is reinforced in the square first post (110) and concrete, cement mortar, epoxy mortar, resin material, etc., capable of withstanding compressive strength is used as a filler between them, it can become a structure capable of withstanding the maximum load of cargo.

[0065] That is, in the prefabricated rack structure according to the present invention, the inner circular post pipe (111) can compensate for the insufficient strength of the outer square pipe, the first post (110), and furthermore, the epoxy mortar can compensate for the insufficient strength of the first post (110) and the post pipe (111) alone, thereby maintaining a mutually stable state. In addition, the exterior of the post pipe (111) can be left without separate post-treatment or only treated with anti-corrosion treatment to reduce paint costs. Furthermore, the size and thickness of the first post (110) can be of the same standard, and the structure can be manufactured to be suitable for the load by adjusting the quantity and thickness of the post pipe (111).

[0066] As shown in FIG. 5, a post pipe (111) and a pair of post clamps (200) into which the post pipe (111) is inserted are embedded inside the first post (110), and as shown in FIG. 3, a pair of fastening clamps (180) are coupled to the outside of the first post (110). To this end, a first bolt hole (112) is provided in the first post (110) as shown in FIG. 5, and a second bolt hole (113) may be provided if an extension part (170) is provided for the extension of the post as shown in FIG. 2. Accordingly, the post pipe (111) can be fixed inside the first post (110) by bolting the post clamps (200) and the fastening clamps (180) through the first bolt hole (112). Also, although FIG. 5 shows a structure provided with a pair of post clamps (200) and a pair of fastening clamps (180), it is not limited thereto, and only one may be applied depending on the load of the items, etc., on which the prefabricated rack (100) according to the present invention is used.

[0067] As shown in FIG. 2, the above post base (130) is provided in a flat plate shape and assembled on the upper and lower parts of each post, so as to support the ceiling and floor portions of the place where the prefabricated rack (100) of the rack structure according to the present invention is installed. The lower post base (130) may be provided in a configuration such as, for example, by performing floor anchoring work at a designated place, adjusting the height, inserting the post, and fastening it with a bolt.

[0068] The horizontal bracing (140) and diagonal bracing (160) may each utilize conventional bracing. As shown in FIG. 2, the horizontal bracing (140) may be connected to the upper and lower portions between the first post (110) and the second post (110'), and the diagonal bracing (160) may be connected diagonally between the first post (110) and the second post (110'). Additionally, the diagonal bracing (160) may be connected alternately in reverse diagonal directions as shown in FIG. 2 to distribute the load between the first post (110) and the second post (110'), thereby forming a truss structure. Meanwhile, holes for bolt fastening with a connector may be provided at each end of the horizontal bracing (140) and the diagonal bracing (160), as shown in FIG. 3 and FIG. 5.

[0069] The above-mentioned load beam (150) is a part that comes into direct contact with cargo in the rack (100) during assembly according to the present invention. It must not have bending, twisting, or sagging, and flatness is important. Accordingly, the load beam (150) can be provided as a first load beam (150) and a second load beam (150'), as shown in FIG. 3. The first load beam (150) and the second load beam (150') can be connected to a pair of connecting bars (152), and the pair of connecting bars (152) can be connected to a combined connector (190) or a load beam connector and a pair of fastening clamps (180) that fit into the combined connector (190) or the load beam connector.

[0070] The above-described load beam (150) can also be provided with the same structure as the post described above. That is, a circular pipe for the load beam, which is fixed by a load beam clamp, is installed inside the load beam (150), and a structure can be applied in which the strength is increased by filling and hardening the parts where bending is expected with cement mortar or epoxy mortar. The mortar can be any material capable of withstanding compressive strength, such as epoxy cement, and even without mortar, a resin material capable of withstanding strength can be filled and used.

[0071] The above extension part (170) may be configured to connect two posts through a second bolt hole (113) to extend the height of the post when the post, which is provided in a certain size according to the present invention, is lower than the ceiling height of the place where it is actually applied.

[0072] Next, the structure and function of the fastening clamp shown in FIG. 5 will be explained with reference to FIG. 6. FIG. 6 is a perspective view of the fastening clamp shown in FIG. 5.

[0073] A fastening clamp (180) applied to a prefabricated rack (100) according to the present invention is provided in a pair as shown in FIGS. 3 and 5 and can be coupled to the outside of a post through a first bolt hole (112) of a post and a fastening bolt.

[0074] The above-mentioned fastening clamp (180) is mass-produced as a standard product by molding methods such as precision casting, casting, die casting, or press molding, and can be used universally regardless of the size or weight of the cargo. As shown in FIG. 6, it may be composed of a fastening body (181) that is roughly square in shape corresponding to the outer periphery of a square post. That is, the interior of the fastening body (181) is provided with a hollow portion corresponding to the outer periphery of a square post, and through this hollow portion, it can be coupled to the post in a fitted state as shown in FIG. 3.

[0075] As shown in FIGS. 4 and 5, a fastening groove (182) is formed in the central portion of the four sides of the fastening body (181) to bolt fasten with the post clamp (200) through the first bolt hole (112) of the first post (110). On both sides of the fastening groove (182), a fastening projection (183) is formed so that a combined connector (190) can be fitted, and a fastening member (184) into which a connecting bar (152) is inserted is provided in the fastening projection (183). A connecting bar (152) as shown in FIG. 3 can be inserted into the fastening member (184) to combine the fastening clamp (180) and the combined connector (190). Additionally, when the fastening clamp (180) is provided as a pair, a connecting hole may be provided in the connecting bar (152) into which an insertion pin is inserted to hold the upper fastening clamp and the lower fastening clamp.

[0076] As shown in FIG. 7, the above-described combined connector (190) may include a connecting plate (191) that contacts the end of the horizontal bracing (140) and / or diagonal bracing (160), a coupling groove (192) provided in the central part of the connecting plate (191) and formed to pass through together with the hole of the horizontal bracing (140) and / or diagonal bracing (160) by a bolt, and a support part (193) that fits into a fastening projection (183). FIG. 7 is a perspective view of the combined connector shown in FIG. 5.

[0077] As shown in FIGS. 3 and 4, a diagonal bracing (160) may be attached to one side of the connecting plate (191), and as shown in FIG. 2, when a horizontal bracing (140) and a diagonal bracing (160) are attached together, they may be connected by bolt-nut fastening through the connecting groove (192) on both sides of the connecting plate (191).

[0078] A semicircular projection is formed on the upper and lower portions of the support portion (193) to fit between the fastening projections (183) provided on each of the pair of fastening clamps (180), and a support member (194) into which a connecting bar (152) is inserted is provided on each of the semicircular projections, and an insertion hole (195) is formed in the central portion of the support portion (193). As shown in FIG. 3, the pair of fastening clamps and the combined connector (190) can be integrated on the outside of the post by inserting an insertion pin inserted through the insertion hole (195) into a connecting hole provided in the connecting bar (152).

[0079] The above-mentioned dual-purpose connector (190) can also be mass-produced as a standard product by molding it using methods such as precision casting, casting, die casting, or press molding, and can be used commonly regardless of the size or weight of the cargo, and may be configured to maintain appropriate strength by changing the material according to the load of the loaded cargo.

[0080] As shown in FIGS. 4 and 5, the above post clamp (200) may include a clamp body (201) having a pipe insertion opening (202) formed in the central part into which a pipe is inserted, a supporting projection (203), and a connecting part (205). As shown in FIGS. 4 and 8, the above post clamp (200) is provided with four supporting projections (203) in the clamp body (201) to contact the inner wall of each square-shaped post, and each supporting projection (203) is provided with a bolt insertion opening (204) that can communicate with the first bolt hole (112) of the first post (110) and the fastening groove (182) of the fastening clamp (180), so that the first post (110), the fastening clamp (180), and the post clamp (200) can be integrated by being bolted. FIG. 8 is a perspective view of the post clamp shown in FIG. 5.

[0081] Additionally, since the pipe for the post (111) inserted through the pipe insertion port (202) is tightened by a bolt inserted through the bolt insertion port (204), the pipe for the post (111) can maintain a certain clearance inside the first post (110). The pipe insertion port (202) can be configured, for example, to allow for the mixed application of 3030 pipes and 3060 pipes.

[0082] Additionally, as shown in FIG. 8, the connecting portion (205) is provided in two between the supporting protrusions (203), and a coupling member (206) is formed in the central part of the connecting portion (205). As shown in FIG. 4 and FIG. 5, when a pair of post clamps (200) are provided, the pair of post clamps (200) can maintain a certain distance from each other by bolting through the coupling member (206) to correspond with a pair of fastening clamps (180).

[0083] Meanwhile, as shown in FIG. 8, the post clamp (200) is provided with a supporting projection (203) and a connecting part (205) protruding from the clamp body (201) to form a predetermined space with the interior of the post, so that when a filling material is supplied into the interior of the post, the filling material can be supplied from the upper part of the post to the lower part through this space.

[0084] The above post clamp (200) may also be mass-produced as a standard product by molding it using methods such as precision casting, casting, die casting, or press molding, and may be used commonly regardless of the size or weight of the cargo, and may be configured to maintain appropriate strength by changing the material according to the load of the loaded cargo.

[0085] As described above, the post clamp (200) is bolted to the first post (110) through the support projection (203) on the side and is provided with a structure through which the pipe (111) for the post passes through the pipe insertion opening (202), thereby achieving the function of dispersing external pressure and realizing the function of connecting the posts through the connecting part (205).

[0086] Next, the structure of the load beam (150) and the connection structure between the load beam (150) and the post will be described with reference to FIG. 9. FIG. 9 is an exploded perspective view to explain the combined state of the post, pipe, and load beam by removing some structures, such as the post and the load beam, from the structure shown in FIG. 2.

[0087] The above-mentioned load beam (150) is in direct contact with the cargo and must not have any bending, twisting, or sagging, and flatness is important, so as shown in FIG. 9, it can be composed of a first load beam (151) and a second load beam (151'), can be provided in a square shape, and can have a circular load beam pipe (153) embedded inside, like a post.

[0088] As shown in FIG. 9, a retaining plate (154) is mounted on the upper part of the first load beam (151) and the second load beam (151'), and a load beam clamp (155) is coupled to the load beam pipe (153) so that the load beam pipe (153) can be maintained inside the load beam (150) while maintaining a certain gap. A filler material can be filled in this gap. The filler material may be any one of concrete, cement mortar, or epoxy mortar.

[0089] That is, in the prefabricated rack structure according to the present invention, the inner circular load beam pipe (153) can compensate for the insufficient strength of the outer square pipe load beam (150), and the epoxy mortar can compensate for the insufficient strength of the load beam (150) and the load beam pipe (153) alone, thereby maintaining a mutually stable state. In addition, the exterior of the load beam pipe (153) can be left without separate post-treatment or only treated with anti-corrosion treatment to reduce paint costs.

[0090] As shown in FIG. 9, the above-mentioned load beam clamp (155) is formed in a roughly cross shape, and a load beam pipe (153) is inserted into the central part, and a protrusion for bolt fastening with a retaining plate (154) may be provided. By means of the protrusion of such a load beam clamp (155), the load beam pipe (153) can maintain a certain clearance within the load beam (150).

[0091] The above-mentioned load beam clamps (155) may be provided in about three places at regular intervals in the central part of the load beam pipe (153), and may also be provided at both ends of the load beam pipe (153) to be combined with the load beam connectors (156).

[0092] The above-mentioned load beam connector (156) is provided to support the load beam (150) and to be connected to the connecting bar (152) to maintain the combined state of the load beam (150) and the post.

[0093] As described above, the connecting bar (152) is provided in pairs, and each connecting bar (152) has through holes provided in the central part and on both sides, respectively, as shown in FIG. 9.

[0094] The upper connecting bar (152) is inserted into the upper support member (194) of the combined connector (190) or the load beam connector (190') and the fastening member (184) of the upper fastening clamp (180) that fits into the combined connector (190) or the load beam connector (190'), and can be coupled to the load beam connector (156) via the load beam connector (156). Additionally, a support pin can be inserted and maintained through the through holes provided on both sides of the upper connecting bar (152) via the load beam connector (156).

[0095] The lower connecting bar (152) is inserted into the lower supporting member (194) of the combined connector (190) or the load beam connector (190') and the fastening member (184) of the lower fastening clamp (180) that fits into the combined connector (190) or the load beam connector (190'), and can be coupled to the bar coupling part provided at the bottom of the load beam connector (156). In addition, a support pin inserted through the through hole of the upper connecting bar (152) can be inserted and maintained in the through hole provided on both sides of the lower connecting bar (152).

[0096] As described above, the first load beam (150) and the second load beam (151') can be kept flat without bending or twisting sagging between the first post (110) and the second post (110') by a pair of connecting bars (152).

[0097] FIG. 10 shows the load beam connector (190') illustrated in FIG. 9. Since the load beam connector (190') is used exclusively for the load beam (150), the connecting plate (191) illustrated in FIG. 7 is removed as shown in FIG. 10, and since the other components are identical, the description of the support member (193), etc. is omitted.

[0098] The above-mentioned post base (130) will be described in detail with reference to FIG. 11. FIG. 11 is an exploded perspective view of the post base shown in FIG. 2.

[0099] The above post base (130) may include a base plate (131), a guide plate (132), and a post clamp (200) as shown in FIG. 8, as illustrated in FIG. 11.

[0100] The base plate (131) is provided on the upper part of the post as shown in FIG. 11 to support the ceiling and floor portions of the place where the prefabricated rack (100) of the rack structure according to the present invention is installed, and is provided in a flat plate shape with a circular opening in the central part through which a pipe (11) for the post can pass, and can be bolted to the guide plate (132). That is, holes for bolting to horizontal bracing (140) are provided on both sides of the base plate (131), and four bolt and nut fastening holes may be provided around the circular opening.

[0101] The guide plate (132) is provided in the shape of a flat plate with a roughly square shape to be fitted into the interior of the post from the lower part of the base plate (131), and a circular opening is provided in the central part through which the post pipe (11) can pass, and four fastening holes corresponding to four bolt and nut fastening holes provided in the base plate (131) are provided around this opening. Meanwhile, the post pipe (11) can be positioned in the central part of the post by inserting and holding the post pipe (11) through the opening of the guide plate (132) fitted into the interior of the post.

[0102] Additionally, the base plate (131), guide plate (132), and post clamp (200) can be maintained as a single unit in the post by fastening the coupling portion (206) of the post clamp (200) provided at the bottom of the guide plate (132), the fastening portion of the guide plate (132), and the hole of the base plate (131) with a bolt and nut.

[0103] In addition, the post clamp (200) is fixed inside the first post (110) by bolting the four bolt inserts (204) provided in the post clamp (200) through the bolt holes provided on the four sides of the first post (110), so the post base (130) can also be fixed to the post.

[0104] The above extension part (170) will be explained with reference to FIG. 12. FIG. 12 is an exploded perspective view of the extension part shown in FIG. 2.

[0105] The extension portion (170) is provided to extend the length of the post and is formed by connecting the upper post and the lower post through the second bolt hole (113) provided in the post, as shown in FIG. 12. That is, the connecting plate (171) is provided corresponding to each of the four sides of the upper and lower posts, and the length of the post can be extended by fastening it with a bolt through the second bolt hole (113) provided in the upper post and the lower post, respectively. Meanwhile, FIG. 12 shows a structure in which four connecting plates (171) are provided corresponding to the four sides of the post, but it is not limited thereto, and a structure in which two connecting plates (171) are provided in an L-shape, for example, may also be applied.

[0106] In addition, in the extension part (170) according to the present invention, a post clamp (200) illustrated in FIG. 8 may be applied to further strengthen the connection state between the upper post and the lower post. That is, as shown in FIG. 12, a pair of post clamps (200) are provided that are fastened through a coupling member (206) provided in the connecting part (205) at a certain distance by a coupling bolt (172), and the upper post and the lower post can be firmly connected by bolting the bolt insertion part (204) of the pair of post clamps (200), the second bolt hole (113) provided in the upper post and the lower post respectively, and the coupling plate (171).

[0107] The assembly process of the prefabricated rack structure described above is explained below.

[0108] First, in a manufacturing plant for a prefabricated rack according to the present invention, a plurality of posts (110), post bases (130), horizontal bracing (140), load beams (150), diagonal bracing (160), pipes (111) embedded inside the posts and load beams, fastening clamps (180), post clamps (200), and connectors (190) are provided.

[0109] Next, as illustrated in FIG. 4, the pipe (101) is inserted into the post clamp (200) and the pipe (101) is embedded inside the post (110) and / or the load beam (150). Then, the post (110), the post clamp (200), and the fastening clamp (180) are bolted together, and the post base (130) is attached to the upper and lower parts of the post as shown in FIG. 11.

[0110] In the prefabricated rack structure according to the present invention, as described above, a post clamp (200) and a fastening clamp (180) can be attached to the post at the manufacturing plant and shipped.

[0111] Next, at the work site, a rack structure can be formed by assembling a horizontal bracing (140), a load beam (150), and a diagonal bracing (160) through a connector to a post equipped with a fastening clamp (180) as described above. In the assembly process described above, the diagonal bracing (160) can be joined into a truss structure as shown in FIG. 2.

[0112] Meanwhile, if the length of the post needs to be extended at the site, as shown in FIG. 12, a post with an extension part (170) provided at the site may be provided.

[0113] Although the invention made by the inventors has been specifically described according to the above embodiments, the present invention is not limited to the above embodiments and can be modified in various ways without departing from the gist thereof.

[0114] By using the prefabricated rack structure and assembly method according to the present invention, quality can be improved through the standardization of parts in a way that reinforces the internal structure.

Claims

1. A post arranged vertically, A post base connected to the upper and lower parts of the above post, respectively. A horizontal bracing connected to the post adjacent to the post base, A plurality of load beams connected to the post between the horizontal bracing, It includes diagonal bracing joined in a truss structure diagonally with respect to the post between the horizontal bracing and the load beam and between the plurality of load beams, and A prefabricated rack structure characterized by having a pipe embedded inside the above post and / or the above load beam.

2. In Paragraph 1, A prefabricated rack structure characterized by having a filler material filled inside the above-mentioned post.

3. In Paragraph 2, A prefabricated rack structure characterized in that the above-mentioned filler is one of concrete, cement mortar, epoxy mortar, or resin material.

4. In Paragraph 2, The above post and / or the above load beam is formed in a square shape, and A prefabricated rack structure characterized by the above pipe being circular.

5. In Paragraph 4, It further includes a post clamp mounted inside the above post and into which the above pipe is inserted, A prefabricated rack structure characterized in that the above-mentioned post clamp includes a supporting projection provided to contact the inner wall of each of the posts and a connecting portion provided between the supporting projections.

6. In Paragraph 5, It further includes a fastening clamp coupled to the outside of the post through a bolt hole of the post, and The above-mentioned fastening clamp is provided with a plurality of fastening protrusions, and A prefabricated rack structure characterized in that the above-mentioned fastening clamp is coupled to the above-mentioned post and the above-mentioned post clamp through a fastening groove.

7. In Paragraph 6, The above horizontal bracing, the above diagonal bracing and / or a connector connecting the load beam and the fastening clamp is further included, The above-mentioned fastening clamps are provided as a pair, and A prefabricated rack structure characterized in that the connector is coupled between the fastening protrusions of the pair of fastening clamps.

8. In Paragraph 7, It further includes an extension part provided to extend the length of the above post, and The above extension includes a connecting plate that connects the upper post and the lower post through a bolt hole provided in the post, and An upper post clamp and a lower post clamp are respectively installed inside the upper post and lower post, respectively, and The upper post clamp and the lower post clamp are fastened at regular intervals by means of connecting bolts through connecting members provided in the connecting part, and A prefabricated rack structure characterized by the upper post and the lower post being connected by bolting the bolt insertion holes of the upper post clamp and the lower post clamp, the bolt holes provided in the upper post and the lower post, and the connecting plate.

9. In Paragraph 8, The above-mentioned load beam includes a first load beam and a second load beam, and Each of the first and second load beams has a load beam clamp built into it to maintain a constant clearance of the pipe, and The first and second load beams are joined by a pair of connecting bars, A prefabricated rack structure characterized by the above pair of connecting bars being inserted into and joined to the above connector. 10.(a) A step of providing a post, a post base, horizontal bracing, a load beam, diagonal bracing, a pipe embedded inside the post and the load beam, a fastening clamp, a post clamp, and a connector, (b) inserting the pipe into the post clamp and embedding the pipe inside the post and / or the load beam, (c) A step of combining the above post, post clamp and fastening clamp, (d) a step of joining the post base to the upper and lower parts of the post, (e) A method for assembling a prefabricated rack, characterized by including the step of connecting the fastening clamp and the horizontal bracing, the load beam and / or the diagonal bracing through the connector.

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