Artificial Stone Cast Rack Storage Unit for Precision Automation

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Solution Overview

Problem

Existing rack storage units for automation systems face challenges in achieving high precision and cost-effectiveness due to manufacturing tolerances of individual components, requiring complex alignment and measurement processes.

Innovation Solution

A rack storage unit with a base frame produced as a one-piece cast body from artificial stone, featuring interfaces for placement devices held by adhesive force, which eliminates component tolerance issues and allows for precise geometric relationships, along with insert parts for additional support and anchorage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If rack storage units are built from many individual metal or concrete components, then manufacturing flexibility and ease of assembly are improved, but manufacturing precision deteriorates due to cumulative tolerances requiring individual alignment and measurement

Engineering Contradiction:
Improveease of assemblyVSAvoidstorage location precision
Core Design Contradiction:
Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent merges multiple individual components (rack stand, rack side parts, and mounting surfaces) into a single integrated base frame cast body made of artificial stone. This unified structure eliminates the cumulative tolerance problems that arise when assembling multiple metal or concrete components, as all reference surfaces and mounting interfaces are formed in one casting process with consistent geometric relationships throughout the entire structure.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The patent employs artificial stone as a composite material for the base frame, combining the benefits of dimensional stability and precision of stone materials with the ability to incorporate metal insert parts for mounting functions. This composite approach allows the structure to achieve high manufacturing precision while maintaining ease of assembly, as the artificial stone can be cast into complex geometries with integrated mounting surfaces and recesses for the metal inserts.

Inventive Principle:
Principle #40Composite materials

2Manufacturing precision

If individual metal components are used with tight tolerances, then manufacturing precision is improved, but device complexity and manufacturing cost increase due to complex manufacturing processes and elaborate measuring operations

Engineering Contradiction:
Improvestorage location precisionVSAvoidmanufacturing process complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent combines the functions of multiple precision-manufactured metal components into a single artificial stone base frame that is cast with integrated reference surfaces, mounting interfaces, and geometric relationships. This eliminates the need for complex manufacturing processes and elaborate measuring operations that would be required to assemble multiple individual components with tight tolerances, as the precision is built into the casting process itself.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The artificial stone base frame serves itself by providing all necessary reference surfaces, mounting interfaces, and geometric relationships through its own structure, without requiring separate alignment and measurement operations. The casting process inherently provides the precision needed, and the integrated design means the structure self-defines its own mounting geometry rather than requiring external alignment procedures.

Inventive Principle:
Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution enables the production of a highly precise and cost-effective rack storage unit with minimal thermal distortion and adaptable geometry, reducing the need for complex assembly and measurement processes, while ensuring reliable anchorage and precise alignment of placement devices.

Implementation Method 1

interfaces are separately formed insert parts which are held by adhesive force/bonding force in the surfaces of the rack side parts

Methodology Applied
Scientific EffectAdhesive force: Adhesive

Implementation Method 2

the hardening of which is based on chemical binding processes with only minor thermal influences

Methodology Applied
Scientific EffectChemical binding: Chemical Bonding

Data Source

PatentUS10331106B2Rack storage unit and automation system
Publication Date: 2019.06.25 MASCHFAB BERTHOLD HERMLE AG
  • US10331106B2 patent drawing
  • US10331106B2 patent drawing
  • US10331106B2 patent drawing

AI summary

A rack storage unit for use in an automation system for a storage of work pieces and/or work piece pallets and/or tools, which includes a base frame with a rack stand and two rack side parts arranged at a distance from one another, wherein facing surfaces of the rack side parts are provided with interfaces for mounting placement devices. It is provided that the base frame is produced as a one-piece cast body from artificial stone, and that the interfaces are held by adhesive force as separately formed insert parts in the facing surfaces of the rack side parts.